The Iron Age 1937-07-15: Vol 140 Iss 3

FRITZ FRANK President VAN DEVENTER Editor Managing Editor Editor Emeritus Mechinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON Toronto, Ontario Birmingham ALLISON Roy EDMONDS Newark, N. J. St. Louts Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Offices Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th St., New York, OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Ouba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, 25 cents. Cable Address, 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. B. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 239 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh D. C. Warren, P. O. Box 81, Hartford, Conn Asa JR. 15, 1937 Hot Hardness Simplified Alloying for Wear Resistance Influence Power Factor Costs Drop Forgers Adopt Standard Tolerances Rate Activity Capital Goods Automotive Industry Statistics Metal-Working Activity Washington News ...... NEWS CONTENTS Plant Expansion and Equipment Buying w Just Between Two Products Advertised Index Advertisers Copyright 1937 Chilton Company (Inc.) her es | | +. 29 | 39 63 132 160 | Se How VisControl makes better, more dependable steel for sheets The slag the principal tool used the melter refining steel. specific intervals, early the the operator tests the viscosity the slag with this device. Interpreting the measurements charts and tables, accurately forecasts additions required bring both sveel and s/ag within correct range end heat. Never before could steel makers accurately predict all properties steel because some depended not only analysis but also slag composition. VisControl makes possible the control these hereto- fore uncontrolled properties—hence production steel that uniform and every respect. RESULT VisControl, Bethlehem’s exclusive process for the control steel-making. VisControl has made possible turn out sheets that not only are better respect deep-drawing qualities but that show consistently good characteristics through heat after heat. When introduced VisControl our plants convinced that would result better processing qualities sheets. The reaction that have received from the who convert flat steel into intricate shapes more than out the results our own tests. JULY 15, 1937 ESTABLISHED 1855 Vol. 140, No. About political danger involved blindly and persistently throwing its weight the Lewis labor minority. How else can one explain the remarkable about-face Madam Per- kins the matter the legality sit-down strikers. Surely, was not change heart but rather change orders that brought about this reversal form one who has been such ardent supporter the are indications that the Administration last beginning recognize the The political mind hard fathom but you can always count upon its highly devel- oped instinct self-preservation. may have recognized, rather late perhaps, the fact that the Administration was helping build engine for its own destruction, creating monster which its maturity would turn upon and rend its maker. How- ever may be, from now on, CIO will have harder sledding. will have earn what comes it. Thus far, has not earned what has gotten. did not earn victory Flint, Detroit, even though won decision. pugilist cannot said have won contest when the referee and timekeeper sandbag his adversary for him. not hard for union organizer membership when has the backing important Federal departments, state and local governments, and when the state militia subject his orders. Even some our early Christian forebears recanted under less impressive persuasion. Probably some them had their fingers crossed. The average worker not censured for joining the ClO unions, any other organization for that matter, led believe that the cost not signing the dotted line may the loss his job his health and home. And especially re- ceived, many workers have, letter purporting come from the President, urg- ing him enroll under the Lewis leadership.* Forcing man sign union application much easier than get him continue pay his dues, especially has joined with his fingers crossed. Mr. Lewis suffi- ciently keen strategist realize this and knows that unless can secure the closed shop and the check-off, the CIO balloon deflate rapidly inflated, once the government pressure and backing are removed. Undoubtedly the CIO management has hoped against hope that the inevitable rift with the Administration could postponed until the second step had been taken and the closed shop and check-off forced upon industry. looks though Frankie and Johnny had come the parting the ways. It's about time! See THE IRON AGE, Feb. 1937, page 55. x ~ es. ™ i for ect nen _ ears L 3 used for making hot hardness determinations means hot Carboloy ball. Wissler, Union Carbon Carbide Research Labor- ABOUT years ago, vanced new concep- tion mechanical hardness technical matter and its significance for modern metal- lurgical testing. The original paper describing the results these fundamental researches appeared under the title “Hardness Num- bers and Their Relations”, THE IRON AGE, 1925, pages 770 773. principle, Holnagel’s observa- tions established the similarity be- tween the well-known stress-strain curves the tensile test and the graphical relationship pressure and corresponding depth pene- 30—THE IRON AGE, July 15, 1937 JOHN HRUSKA Metallurgical Engineer, Electro- Motive Corp. tration the indentation hardness tests. The familiar elastic limit, permanent yield and ultimate strengths, followed flow may thus visualized the diagram- matic representations either elastic deformative hardness testing. See Fig. Recent advancements measur- ing hardness more accurately than heretofore possible prompted the writer broaden the scope these comparative studies also over the technically important tempera- ture ranges specific metals and alloys. Modern developments the operation machinery, tools and equipment higher temperatures than ordina- rily experienced few decades ago, have been such magnitude impose increasing require- ments upon testing technique regard the doubtlessly impor- tant indices resistance per- manent compressive deformation. The following deliberation may perhaps serve well illustra- tion this statement: has long been known, that tensile strength together with elastic indenta- tion hardness generally decrease higher temperatures. Quite ex- haustive work was done nu- merous investigators and metallur- gical laboratories computing use- ful tabulations and diagrams espe- cially for such metals which are ° subject mechanically produced directly convected heat. High speed steels the conventional 18-4-1 type and many similar grades tool steels have received particular attention the endea- vor correlate measurable service performance with that property designated presently “hot hard- ness”, i.e., the variation re- bound hardness with temperature, shown Fig. This work with highly alloyed tool steels, the scant published data other metals, addition the author’s experiments, were the present article with view establishing some diagrammatic mathematically expressible equations for the future simplification similar studies hot hardness. Types Tests Hardness elevated tempera- tures and more accurate methods its testing have engaged the interest many investigators, es- pecially since the discovery high speed steels Taylor and White. Thus, was only logical that the first attempts measure hot hardness were made after the in- troduction the ball indentation test Brinell. The devel- opment nearly every instrument intended for static dynamic | | 5 - o ¥ | | hardness testing was similarly ac- companied some experimenta- tion the field higher tempera- tures. interesting note, however, that practically all the early research work along these lines was handicapped some discrepancy the testing appa- ratus parts thereof, necessitat- ing abandonment that method for the intended purpose. The rapid advancement the production highly heat resist- ing metals together with the steadily improving accuracies essential testing apparatus during the last decade suggested numer- perature between the ball and specimen. The “cold ball” method, however, considered many the most practical all hot hard- ness tests. objection order minimize the area the chilling effects the mm. Brinell ball during the sec. re- quired for standard Brinell test, the present writer used ball tungsten carbide con- junction with standard Rockwell testing apparatus and under 100 kg. load, with truly grati- fying results. Duplicate tests show satisfactory agreement. Limit Hardness kg. Depth 1/5000 in. ous renewed efforts correlate the anticipated changes hard- ness with increasing temperatures. Hence, inconsistencies derived from the known softening steel balls during the conventional 30-sec. contact with the hot practiced during the Brinell test— focused attention metallurgists upon the application tungsten, and other thermally stable car- Table gives comparative data for three different types balls. Note the different limits temperature for each type, and, also, the vari- ation flattening the balls various Brinell hardness numbers. Consequently, and mm. balls the newly discovered materials were used standard Brinell ma- chines. Highly informative tests were conducted this manner with either cold ball pressed into the hot metal with the impresser held the temperature desired for the test piece, thus eliminating the ABOVE gram for eutectoid tool tron tests). Brinell Hardness Numbers RIGHT 1G. 2—Hot hard- ness curves for high speed and car- bon tool steel. 400 has also been found review- ing available reports and actual experimentation, that hardness tests with carbidic balls are far more consistent and are naturally less expensive than most the indentation hardness tests utilizing diamond pyramids diamond balls. The latter objection appar- ently eliminated broader use these tests for investigation hardness characteristics metals higher temperatures. making the tests with Rockwell appa- ratus, the top and bottom surfaces the specimen should smoother than ordinary shop testing. will shown later that the tests carried out means this method are readily convertible into Brinell numerals, enabling more comprehensive discussion con- clusions. The apparent objection the above indicated ball indentation test pointed towards the applica- tion modified compression test, based the surface deforma- tion caused pressing two speci- mens the tested material against one another. Ever since the con- ception the mutual indentation method measuring hardness metals 1722, Réamur, there have been made various attempts apply this principle also for the measurement hot hardness. Haigh, Foeppl, Cowdrey, Kayser, and Harder have used this test carrying out specific research pro- 2000 Temperature, deg. 800 THE IRON AGE, July 500 400 200 100 Brinell Cowdrey and Harder grams. While scientifically more appealing, the Cowdrey and Har- der tests average only 0.9 per cent above those the corresponding Brinell even Rockwell tests with carbide indentors. Kayser’s tests utilizing pyramid pressed against the underlying support, show about the same spread those Cow- drey and Harder, but the average the resultant numerals sev- eral per cent higher than the con- ventional Brinell determinations. Sketches indicating how these va- rious methods function are shown Fig. justice other pro- cedures, must said that the orthodox Brinell tests probably have the same practical magnitude any one the mutual indenta- tions. Several Tests Necessary Very recent work the writer conversions various hardness numerals seems indicate the ne- cessity ascertain hot hardness more than one ‘type testing order give truly reliable index the investigated material for practical purposes. The method testing depends upon the pur- pose for which the information sought. the part used higher temperatures under static load, the ball mutual indenta- tion test entirely satisfactory for giving the desired information hot hardness. the contrary, material subjected repeated dynamic stresses should invariably investigated means some dynamic method test. prin- ciple, dynamic methods hardness testing are based the measure- ment surface deformations, i.e., the elastic rebound physi- cal shock, the energy which ordinarily well standardized with the testing instrument proce- dure. The fundamental law gov- erning the deformative testing hot hardness means dynamic methods may derived from the 32—THE IRON AGE, July 15, 1937 Cone IG. 3—Various schemes used determining hot hardness. LEFT ° ° ° BELOW 4—Graphical lationship between hot hardness coeffi- Kayser cients and melting points various pure 0.0050 Hot Hardness Coefficient 0.0001 nent “n” practically constant for any type tested material. was also found exhaustive tests that “n” equals For alloy having material constant hardness in- dentation (numeral) The specific relationship between the energy and the surface the spherical indentation when 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 Melting Point, deg. following mathematical delibera- tion: equals the energy the fall; the material constant; the diameter spherical impression (if ball used) The above equation may, course, expressed graphically paper. Straight lines should result for ideal conditions testing. Various experiments made with the Poldi, Pellin and Oertel Hardness Testers disclosed the interesting fact that the expo- using standard Brinell ball for the test indirectly indicative the resultant hardness numeral hardness; given the follow- ing deductions: 0.6169 When scrutinizing printed and privately secured diagrams the TABLE Comparison Brinell Balls Used for Hot Hardness Tests Type Ball Composition ball metal, per cent .... Elastic rebound, per cent Safe temperature limit, deg. F.......... Flattening ball (in mm.) at: Hultgren Cold Ordinary Carboloy Worked and Steel Ball Etched Ball Ball 9.998 9.998 9.996 0.3938 0.3938 0.3939 7.7417 4.3084 4.1161 carbon cobalt 87.0 86.3 82.8 1650 400 400 0.000 0.000 0.004 0.000 0.001 0.009 0.002 0.005 0.004 0.012 0.036 Ball 0.0020 0.0010 U 0.0003 | | = Hardness Numbers 100 200 deg. relationship hot hardness and temperature regard their geo- metrical configurations, may inferred with ample justification, that nearly all hot hardness curves metals correspond clearly uniform pattern. The exact curva- tures and slopes will, course, show deviations according the type and composition the steel tested, but—in general—they are geometrically similar. This true irrespective the method used securing the essential data for reliable hot hardness curve. Within the rather narrow limit —50 deg. about +200 deg. C., the mechanical hardness very pure metals changes with varying temperatures accord- ance simple logarithmic curve, the mathematical expression which reads follows: where the hardness numeral te; TABLE ABOVE 5—Hot hard- ness curves lead and complex lead alloy. RIGHT 1G. 6—Hot hard- ness curves (lo- garithmic) cop- per and complex copper alloy. are temperature readings; and the coefficient equivalent tangens in- clination the curve. The hardness numerals should preferably expressed Vickers Brinell units, the temperatures Hot Hardness Coefficients and Melting Points Various Chemically Pure Metals Hot Hardness Coefficient, Metal 0.00120 0.00014 0.00210 Melting Point Absolute Deg. Temperature Deg. 660.0 933.0 1200 320.9 593.9 609 1083.0 1356.0 1981 1535.0 1808.0 2795 327.5 600.5 622 651.0 924.0 1204 1452.1 1725.1 2646 960.5 1233.5 1761 231.8 504.8 449 419.4 692.4 787 should measured converted Centigrade degrees. Physically speaking, the essential coefficient least close agreement with the melting point the metal under consideration. Fig. repre- sents this relationship graphically, and Table lists the actual melt- ing points and coefficients (k) for most the more common indus- trial metals. Since ferrous non-ferrous al- loys are characterized melt- ing range and not clearly defined melting point, this un- doubtedly convenient rule may not applied commercial metals without ample corrections. These 200 400 600 8001000 corrections become complicated, however, obscure the simple correlation mentioned before. rather exhaustive series tests conducted the author with many the important metals used the industries made, therefore, entirely different mathematical treatment technical hot hard- ness curves advisable. Complete hot hardness curves carbon and alloy steels well numerous non-ferrous alloys re- semble the one Fig. repre- senting ordinary high speed steel the 18-4-1 type. may ob- served that during the first few hundred degrees increasing tem- perature the hardness decreased rather slowly. From about 500 deg. C., 932 deg. F., the hot hardness drops abruptly less than 100 Brinell hardness merals. still higher tempera- tures, this low hardness diminishes continuously, until its value reaches zero when melting commences. Mathematical analyses these THE IRON AGE, July 15, 1937—33 5 a, 300 400 500 600 | curves are being conducted present, the results which work shall reported upon their com- pletion, the near future. Preliminary examinations hot hardness curves revealed, however, one interesting common with all metals alloys under consideration. All curves computed ordinary graph paper showed geometrically definable turning point between the concave and the convex portions the curves. the writer’s knowledge very little attention has ever been paid this peculiarity hot hardness curves and yet, seems, that this turning point distinct criterion for various compositions 120 quite evident from these curves, that the logarithmic relationship about 200 300 deg. below the melting point the alloy. This confirms the writer’s previous as- sertion that alloys with changes phase the solid state with melting intervals, not follow the otherwise simple logarithmic cor- relation hardness and tempera- ture above definite temperature. Another similar example the effects alloying elements upon the geometrical configuration hot hardness curves may found when studying copper alloys. The changes hot hardness elec- trolytic (chemically pure) copper 100 Rockwell Hardness Numbers Scale 1200 Temperature, deg. and masses ferrous and non- ferrous metals. Comparisons with- the technically used groups alloys, such the one shown Fig. would certainly prove this contention. Hot Hardness Metals and Alloys While has been shown the foregoing discussion that chemi- cally pure metals are governed logarithmic relationship between hardness and corresponding tem- peratures, the question arises now whether the influences relatively small additions impurities have marked influence upon the gen- eral trend their hot hardness order demonstrate this difference the hot hardness curves the purest obtainable lead was compared with modern bearing alloy containing several other in- gredients addition the lead base. The analyses both speci- mens are shown Table III. values were then plotted dia- grammatic paper (See Fig. 5). 34—THE IRON AGE, July 15, 1937 hard- ness curves carbon alloys. corresponds about 1120 deg. the following equation: Above this temperature propor- tional permanent yield and flow modify the trend the hot hard- ness curves one the convex type. This property remains some- thing like criterion all alloys containing copper. comparison with rather complex copper- aluminum-iron iron alloy will prove TABLE Analyses Pure Lead and Bearing Alloy Chemically Pure Bearing Lead, Alloy, Per Cent trace 0.18 nil 0.06 Not determined ....... 0.001 0.46 TABLE Analyses Pure Copper and Complex Alloy Aluminum- Iron- Electrolytic Copper Copper, Alloy, trace 7.59 0.003 Not determined ........ 0.004 0.26 the existence this rather pe- culiar finding. Table gives the composition the copper and the alloy used this investiga- tion. The hot hardness curves both metals depicted Fig. are self- explanatory. The importance distinct turning point hot hardness curves becomes still more apparent the behavior ferrous alloys metals. Vacuum melted electro- lytic iron, for example, marked the following equation: This admittedly simple expres- sion becomes rather obscure the intentional addition such metallurgically common elements carbon, manganese, nickel, chrome, etc. Although was outside the intended scope this paper study the effects each the possible combina- tions the various elementary alloying constituents technical iron steel, nevertheless, the in- fiuence carbon upon the relative outline the corresponding hot hardness curves ordinary steels should interest any discus- Fig. illustrates graphically the changes Rockwell hardness—de- carbide ball 100 kg. load—with should naturally pointed out that generally applicable conclu- sions should not drawn from these diagrams, since they not represent but tests with commer- cially produced steel not vacuum melted alloys the the- oretical carbon-iron alloys. How- ever, the relative values are prob- ably not displaced for ordinary open-hearth grades with analyses close those the employed specimens. { * oO \ ad | : Simplified Alloying for and Corrosion Resistance ordinary cast iron, mild steel, even copper into corrosion-resisting alloy that will meet present-day requirements sounds very much like while achievement. able easily, and relatively cheaply, almost any sort metal melt- ing arrangement adds the im- portance the process, and, while further developments and greater perfection procedure are the offing, enough ground gained this new method alloy- ing demand the interest every metal maker and machinery fab- ricator. Wear metals aren’t new objective. Metallurgists have already gone long way their development and many usable metallic alloys for such services are the market and use. For the most part, though, they are quite complex alloys which possess out the ordinary physical properties that hamper their more general adop- tion. The metals resulting from this newest alloying procedure have quite simple composition and the base metals retain most their characteristics, through temperature changes concerned, yet they take the added qualities necessary for longer useful life severe service. According popular conception, wear reduces the size and weight body rubbing off particles crystals have been formed into with various percentages pure electrolytic nickel. The author herein describes the introduction this into baths molten cast iron, copper, which procedure results greatly increasing the corro- sion and wear resistance the base metal. while sliding frictional con- tact with another body. More often than not machinery and equipment users fail recognize the presence any destructive agency other than pure abrasion and hold the theory that glass- like hardness, especially upon the surfaces contacting metallic parts, should and the acme wear-resistance preparation. sense the word this true conception either wear itself wear-resistance. there should other corroding, erod- ing similar damaging and de- structive agencies present, oxida- tion and galling must reckoned with. Rarely, except very care- fully prepared apparatus, pos- sible have abrasion without it’s being accompanied least one the several other metal destroy- ing agencies. Consequently, when planned resist the ravages abrasive wear, there should also preparation against the ravages corrosion, erosion, electrolysis, ° MILES SMITH ° galling and oxidation. this re- cently developed method alloy- ing, described following para- graphs, all these factors are taken into account. Much has already been said about the metallic boride crystals which were invented some five years ago Norman Cole, Coast metallurgist who has specialized so-called hard metal developments since their inception. There have also been discussions the fact that these crystals, produced Mr. Cole’s process, consist mixture extremely high melting point boride crystals and boride crystals much lower melting point, which mixture will readily alloy with practically any base metal except aluminum, lead, and copper. But the scheme forming these crystals into mother with various percentages pure electrolytic nickel and introduce this mother into baths molten cast iron, steel and copper quite new. this latter process which now avail- able for practically anyone’s adop- tion, and which produces simple and useful alloys with most inter- esting characteristics. Again contradicting the popular conception the ideal wear-resist- ing metal, the best alloy for such service one which needs not have any great degree hardness, either upon the surface through- out its entire body, but must possess density and molecular co- hesion that will resist the rubbing off tearing away one more THE IRON AGE, July 15, 1937—35 | 5 | { | re ad pay | a | | | q 4 A. left right: Pure gray cast iron, cast iron and per cent mother and cast iron and particles from the whole piece. other words, should tough. could resilient, much the better. Surface density “work hardening” also beneficial for wear resistance, and pronounced resistance corrosion and oxidation And, along with all, should induce low frictional coefficient. Today, there are three major processes for securing wear and corrosion resistance: heat treating, hard facing, and compounding alloying. All three methods have their good and their bad points, their records achievement and failure, their ideal applications and the services for which they are entirely unsuited. been spent and years will spent effort determine and classify abrasive corrosive agencies and the ways best com- bat them, but very doubtful they ever can accurately handled any “rule thumb.” Yesterday, today and, undoubtedly, tomorrow, experimenters will trying this and trying that with definite guarantee beforehand that they will 100 per cent suc- cessful. Heat treatment, unless the metal heat treated non-oxidizing and corrosion-resistant, can hardly considered satisfactory prepa- ration process resist severe wear. applications where the service light and where lubrication cuts down the possibility galling, oxidation corrosive action, well wear, either surface preparation heat treatment throughout the piece will lengthen its useful life. For more severe service, heat treatment 36—THE IRON AGE, July 15, 1937 per cent mother. All views 100 diameters. 2—Mild low-carbon steel (left), and (right) mild steel and per cent mother (boride crystals and nickel). Both views 100 diameters. far from completely satisfac- tory. the other hand, hard facing produces entirely different kind surface protection than heat treating, and can resist corro- sive well abrasive agencies. However, hard facing also has its limitations well its ideal ap- plications. Most often, though, the failures hard facing are caused something other than failure the hard facing metal itself. The layer wear-resistant, corrosion- resistant alloy often sponsors trou- ble and failures the parent metal the hard faced assembly which discourage wider use the process. The ideal way resist wear and corrosion is, course, solid metal which possesses all the desired characteristics. other words, wear and corrosion resistant alloy that easy produce, not pro- hibitive cost and which can readily worked into the shapes desired and required. These new easily compounded alloys may not have every desired property, yet there every reason believe that they come nearer the ob- jective than any metals far in- troduced. Colmonoy, Inc., Los Nietos, Cal., produces Mr. Cole’s develop- ments commercially, and alloys the metallic boride crystals and pure electrolitic nickel varying pro- portions from per cent nickel and the balance crystals, per cent nickel and per cent crys- tals. the latter analysis which has been found most suitable for the mother alloying substance. This mother has melting point approximately 1850 deg. F., but, since contains easily oxidized gassified elements, can super- heated far above its normal melting point without any loss > _ properties change chemical content. fusing this mother varying percentages iron copper, alloys with most interesting physical and chemical characteristics may ob- tained. Furthermore, the percent- ages the base metal and the mother may varied meet indi- vidual needs each type ser- vice. order better bring out the possibilities and effectiveness this new alloying procedure, pertinent draw few compari- sons and study the various resul- tant metals over range percentages base metals and al- loying mother. Rockwell hardness readings will used show aM phuric acid solution decreased 1.07 per cent. raising the mother percentage 25, the Rock- well hardness drops another point but the loss the acid solution only 0.32 per cent. These alloys, contrast the one made with the pure crystals, are tough, with very dense structure, and resist fracture. Mild low-carbon steel, when alloyed with the nickel crystal mother the percentage steel and mother, becomes metal which has Rockwell hardness and 100-hr. loss the sulphuric acid solution 0.53 per cent. the same mild steel alloyed with the pure crystals the same proportions the cast a Section through pure copper wire, diameters. Pure copper and per cent mother 100 diameters (right). changes density, and the per- centage loss weight when submerged one part sulphuric acid and four parts water for 100 hr. will used indicate the change corrosion resistance. Ordinary cast iron, alloyed with per cent weight the pure metallic boride crystals pro- duced Mr. Cole, will form metal that has Rockwell hard- ness 62, density 7.55 and 100-hr. loss 8.09 per cent sul- acid solution. This metal very brittle and entirely un- suited for use machine part. Should per cent weight the nickel-erystal mother added the same ordinary cast iron, the Rockwell hardness will and the 100-hr. loss the acid so- lution will 65.91 per cent. How- ever, the percentage mother increased per cent, the hard- and the 100-hr. loss the sul- iron was alloyed with the pure crystals, alloy secured which and density 7.56, but the 100-hr. loss the 4:1 sulphuric acid 62.15 per cent. solu- tion one part water and one part nitric acid, the 100-hr. loss weight this pure crystal and steel alloy only 0.13 per cent. While the loss the metal made with the per cent mother per cent the same nitric acid so- lution. Thus, just because metal resists one type corrosion doesn’t mean that will resist every type corrosive agent. Copper takes some most in- teresting physical characteristics when alloyed with the nickel crys- tal mother. Only per cent the mother, added pure electrolytic copper, increases the density the copper alloy from per cent over that pure copper, and the increased resistance acid at- tack very noticeable. When per cent the mother added, the hardness jumps Rock- well scale and, with per cent mother, the scale hardness be- give better idea the structural changes made when this alloying mother added copper, the per cent mother alloy shows ultimate strength 27,110 per sq. in. with reduction area 47.5 per cent. The per cent alloy has ultimate strength 43,000 lb. per sq. in. and deduc- tion area only 8.4 per cent. Resorting the microscope, which, after all said and done, tells the true story, becomes evi- dent that some most interesting crystalline structural changes take place the base metal when the nickel metallic boride crystal mother added. Taking cast iron first and examining the pure cast iron, then the cast iron alloyed with per cent mother and next with per cent mother, noticed that there change structure that progresses the percentage mother increased (see Fig. 1). The cast iron shows relatively loose grained crystalline structure which, with the addition only per cent mother, closes very noticeably. The structure the per cent cast iron and per cent mother indicates dense, greatly refined metal that would tually does. Steel—mild shows similar change crystal- line structure with the addition 4—Nickel-boride crystal mother, 400 diameters. Note the very dense structure. THE IRON AGE, July 1937—37 | the alloying mother. The refine- ment and regularity the crystals indicates (see Fig. 2), the case the cast iron, that the re- sultant alloy per cent steel and per cent metallic boride crystal-nickel mother will tough, wear resistant and corrosion re- sistant. the case copper, how- ever, where the crystalline change even more marked. Comparing the magnified cross-section pure copper trolley wire and the photomicrograph the same pure copper after being alloyed with per cent the mother shows marked change structure that the two have little resemblance (see Fig. 3). The large crystals the pure copper have been re- two distinct kinds. Part the crystals the crystalline mixture readily alloys with the nickel the mother and, turn, with the iron, steel copper base metal used and impart that al- loy all the desirable properties incident with the addition boron borides base metal alloys. addition the refining influ- ence, the alloy reinforced generous well distributed quantity metallic boride crystals which not lose their identity and alloy, but which percolate through the mass and are held emul- sion. These indestructible metal- lic boride crystals, formed the heat chemical reaction, are mi- size, diamond hard and well imbedded the mass it- NEW OVERLAY MATERIAL OLMONOY, INC., Los Nietos, manufacturers alloy and overlay metals, has announced new process and material for producing welded-on, fined such degree that hard believe the alloy has per cent pure copper base. All the mentioned alloys show the crystalline structures that they are dense, with tendency toward toughness, and, while none them indicates any great de- gree malleability ductility, there suggestion solid cast- ings. Experience has indicated that such the case. Any the al- loys may cast into practically any desired shape without fear damaging shrinks flaws. But close-grained structure not the only asset these new al- loys. known and has been mentioned, the particular metallic boride crystals used with the pure nickel form the mother are 38—THE IRON AGE, July 15, 1937 wear-resistant, heat-resistant, corrosion- resistant overlay hard facing. This new material consists (me- tallic boride) paste contained col- lapsible tin tubes, illustrated. This paste may squeezed out and spread over the surface processed and then sweat into the surface the parent metal with the flame the oxy-acety- lene torch, the atomic hydrogen torch, the carbon electric arc, furnace heat, form overlay that actually becomes part the metal processed. This sort overlay will not chip off and does not interfere with hot cold forging, forming, heat treat- ment the parent metal. The collaps- ible tube contains sufficient paste for processing from sq. ft. sur- face, depending upon the thickness overlay desired. self. They are non-oxidizing, have film oxide about them, tungsten-carbide crystals often do, and they resist the wearing away the metal well re- tard corrosive action. Yet, strange may seem, these tiny crystals reduce rather than increase both friction and tendency gall. The presence the nickel the alloys requires lengthy expla- nation prove beneficial. Nickel much used alloying element and the properties which in- duces are too well known dwelt upon any length here. might well say, though, that the particular combination the nickel and the metallic boride tals used form the mother alloy produces metal which has well scale and 100-hr. loss 4:1 acid 0.06 per cent. relatively tough break and exceedingly hard grind. may. seen from this that the nickel loses con- siderable degree its character- istic physical properties this close association with the crystals. photomicrograph the nickel- boride crystal mother shown Fig. Quite naturally, any new sub- stance metal more value than the possible extent its use- ful employment, and the same true these new simple alloys. Laboratory metals are interesting, but commercial importance. The first claim the. new alloys the possibility their produc- tion any metal making plant. They are not suitable for cupola production, but any type cru- cible melting arrangement en- tirely satisfactory. Furthermore, they may varied analysis meet the conditions hand. There are delicate metallurgical balances main- tained and the percentages mother and base metal may changed varied will meet the requirements. For example, one present user the new cop- per alloys melts the mother and pure copper 50:50 proportion first and uses small pigs this manufactured alloy feed into his pure copper form the desired final analysis. Melting and re- melting, providing impurities are kept out, has little, any, dam- aging effect the mother its alloys. this day and age, when the addition alloying elements great numbers appears the vogue, would seem that the in- troduction very simple com- positions would getting out step with the times, but actual performance data the new al- loys prove their advantages rather than disadvantages. Present-day industry requiring more and more equipment and the same time demanding considerable in- crease the length the equip- ment’s useful life. The new alloys have opened avenues for at- taining industry’s demands and have shown many fabricators how help themselves out their own difficulties instead being entirely the mercy specialized metal producers. J 7 : 5 *o 4 7 ‘ > _ continuous furnaces for heating slabs are now standard equip- ment steel mills and most these utilize gas fuel. This the type slab heater installed the new hot strip mill the McDonald Fired Slab Heaters ° ° NEALEY American Gas Association works the Steel Corp. addition the low and medium carbon steels such alloy steels Ply-Krome, Cor-Ten, Man- Ten, low metalloid and 18-8 stain- less are also rolled here. The Ohio works the Carnegie- Illinois Steel Corp. supplies steel slabs in. thick, in. wide and ft. length. These slabs are handled crane depiler, which transfers them the furnace entry table, which 175 ft. long and operates speed Gas fired slab heating furnace similar those the McDonald Works the Steel Corp. THE IRON AGE, July 15, 1937—39 ‘ : 268 ft. per min. There are three furnaces, and the slabs are charged into each means ram type motor driven pusher (100-hp. mo- tor). Zone control obtained the use independently fired heating chamber soaking chamber. The first section the furnace divided into two zones, the first long and low roofed and utilizing the waste heat from the rest the furnace preheat the incoming work. Gas Burners Three Groups Heating accomplished with gas burners three groups eight each. The first group over fires the work from the discharge end into the soaking chamber. The other two groups both over and underfire the work, firing toward the discharge end. They are lo- cated the beginning the heat- ing chamber, which ft. high this point. There hearth here and the lower group burners fires into combustion chamber below the water-cooled skid pipes which the slabs ride. This heating chamber controls the tonnage output the furnace, flexibility being obtained varying the amount gas burned. During mill delays the burners can shut off entirely save practi- all the fuel. The soaking chamber utilizes from per cent the fuel requirements the entire furnace and main- tained the temperature required the discharged material. formity heat distribution re- here. This chamber has solid refractory hearth generally covered with chrome ore and heav- ily insulated beneath. The skid pipes end where the hearth begins, the slabs being pushed over the hearth where any black spots caused the water-cooled skids are re- moved. The capacity the fur- nace increased underfiring the heat applied both sides the work the same time. Heats Tons Steel Per Hour End charging and end discharge are employed and the doors are motor operated provide minimum heat losses. The hearth dimensions each furnace are ft. and the capacity gross tons steel. Fuel consumption approx- imately 1,650,000 B.t.u. per ton steel heated per hour. recuper- ator the tubular type preheats the air for combustion. This con- sists two preheating chambers with collecting chamber between. Each preheating chamber consists bank horizontal refractory tubes through which air drawn into the collecting chamber. This air preheated the hot waste products combustion which are drawn down around them from the furnace. This preheated air de- livered exhaust fans the gas burners from in. pres- sure and 800 deg. Stack tem- peratures are deg. While observation pulpit located between the pushers two these furnaces, each the three furnaces has individual control panel. these are mounted flow and pressure meters and air fuel ratio meters. Included are com- plete combustion for each the three zones, three indicators, indicating the gas flow each zone, gas pressure regulator, furnace pressure regulator for controlling the stack damper, recorder record the total gas burned, fur- nace pressure recorder, CO, re- corder and three-point tempera- ture recorder which records the temperatures stack gases, pre- heated air and waste heat entering the recuperator. these control panels centers the entire furnace manipulation. Discharged onto mill table the roller type, the hot slabs are delivered the first mill stand the rate 208 ft. per min. Entirely separate from the delivery table, and opposite the discharge door friction gear shaft against which the slabs impact ejection. the reconstruction the New York Central right way the West Side New York City remove trains from street level, the railroad tracks have been submerged and new buildings are being erected over the tracks, in- volving some unusual features steel construction. illustra- tion shows the new plant the Farms Co., being built will take milk for New York City from milk tank cars and pump directly into tanks 40—THE IRON AGE, July 15, 1937 : > ( 3 | Side-Tilter for Strip Steel Conveyors Has Longitudinal Leveling Feature CARL PLOCK Engineer, Logan Co., Louisville, Ky. strip steel are handled their sides trough-type roller con- veyors. intervals along the con- veyor line the end the line, the coils are transferred mechanical means picklers, un- method transfer incorporates tilting trough section from which the coils are discharged from one side the conveyor. some cases this coil discharg- ing accomplished raising the opposite side the tilting section, thereby lifting the entire weight the coil and swinging the entire tilting section through substan- tial arc. another arrangement, recently developed the Logan Co. and here illustrated, one side the trough conveyor section held stationary and the other side dropped just enough cause the coils roll off smoothly and gently. Thus the load dis- charged being lifted. Most trough roller conveyor lines are pitched longitudinally that the coils will travel gravity. modern steel plants coils side-tilting unit this slope may prevent the coils from discharging exactly right angles the main conveyor line, although right angle discharge always preferred and frequently considerable importance. meet this require- ment, the new Logan type side-tilter has been designed include automatic self-level- ing feature, means which the entire unit lowered longi- tudinally horizontal position before the side-tilting action be- gins. shown the illustration, the entire mechanism pivoted transverse shaft the low end and supported positively the high end two leveling cams operating flanged wheels. The side-tilting also cam controlled. The drive, consisting motor and speed re- ducer, carried cradle rigidly fixed the main moveable frame- work. Operation this leveling type side-tilter follows: Coils ar- riving the tilting section are held check escapement The new Logan leveling-type side-tilter the carrying position shown the left; the same unit with the drop-leaf lowered discharge coil strip steel pictured below. The structural framing this tilter was designed for setting pit, but may varied suit requirements. type air-operated brake the con- veyor line just ahead the tilting section, the escapement principle being used that coils can re- leased one time. When re- leased, the coil moves the tilting section and stopped proper position another adjustable bumper plate equipped with heavy coil springs absorb the shock. The adjust- able feature provides for centering various size coils with respect processing handling equipment along the conveyor line. With the coil thus position, the operator pushes button start the motor, whereupon the en- tire tilting unit first levelled longitudinally horizontal. Next, and with the trough section still horizontal, the drop-leaf low- ered. When fully lowered the drop- leaf engages limit switch which stops the machine, the coil then rolling straight off the conveyor section. This done, the operator pushes the motor-start push button again quickly return the tilting section its original position the trough line, where stopped another limit switch. During the entire operating cycle the machine, for which patent applica- tions have been made, the power unit called upon lift the empty tilting section only and through very small arc; the loaded section always lowered. THE IRON AGE, July 15, iy a The prehensive series the Economics Industrial Power Transmission. the very nonchalant at- titude many produc- tion executives the subject low power factor operation. Where power purchased from public utility and the utility imposes penalty for low power factor, the question assumes serious proportions; but where such penalty imposed, where the power generated within the plant itself, the tendency many cases seems think that power factor impor- tance the production scheme. That attitude probably based more lack knowledge than any intentional disregard facts. true that the subject dif- trical engineers have not, unfor- tunately, made any easier un- derstand, with explanations that not really explain. But the lack understandable explanation does not remove the extra cost low power factor operation, any more than the old farmer’s remark first seeing giraffe the circus, “There ain’t sech animal,” makes the giraffe non-existent. There penalty paid for low power factor operation, whether appears monthly power bill, buried among unseen costs operation; and that penalty production costs. How much that cost amounts the course year varies with many conditions. have known cases where came one-quarter the entire power cost. any plant where power costs run into many thousands dollars per year, the extra and un- necessary cost low power factor operation factor considerable importance. simple explanation power factor, 42—THE IRON AGE, July 15, 1937 and possible understand clearly just what its influence production costs general. One does not need electrical engineer grasp the facts, be- cause, fundamentally, the problem one economics, and only in- proaching the matter from eco- nomic viewpoint, therefore, the mystery yields persuasion. What Power Factor? Electricity made useful work for mankind driving ma- chines being transformed into mechanical energy motor. terms, machine which elec- tricity, flowing through coils wire disposed certain fashions, sets fields magnetic force and causes rotating member cut these lines force progressively, thus making the rotating member turn its shaft and communicate driven machine. direct cur- rent motor the field the armature windings are always elec- trically connected some way. Consequently the current which “energizes” the field winding and sets the field magnetic force passes also through the armature winding cause the rotational ef- fort cutting those lines force. The current flows continuously through both windings, creating magnetic field and causing the armature winding cut the lines that field, all one operation. brief, the energizing effect and the effect causing rotational effort, are one and the same, and insep- arable. 100 kw. uence Power Factor alternating current induction motor entirely different prop- osition. There electrical con- nection between the stationary and the movable parts such motor. The electric current flowing from the generator the field windings the motor (called the primary circuit) never touches the rotor. The magnetic effects the rotor (or secondary circuit) necessary cause rotation, are induced the rapid reversals current the primary circuit windings. But the alternating current flowing from the generating source through the primary windings induction motor differs one very important respect from direct current. per- forms the double function ener- gizing the magnetic field and inducing entirely separate flow current the secondary cause rotational, “lines force cut- ting” effect, one and the same time, but with two separate efforts. (An electrical engineer might not agree with the wording this statement, but trying make the explanation very simple.) One these efforts (the lines force cutting) the result the actual flow current. may measured wattmeter and ex- pressed kilowatts. When you buy el