The Iron Age 1937-09-30: Vol 140 Iss 14

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus \lachinery Bditor Art Bditor Metallurgical Hditor Associate Editors JURASCHEK Consulting Editor Washington Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati Boston Hambura, Germany Milwaukee San Francisco Toronto, Ontario Birmingham Vewark. N, J. St. Louis TURNER Buffalo Owned and Published CHILTON COMPANY Publication Offices Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ J. 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 FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subescrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00 Can- ada, $8.50 Foreign, $12.00 year. Single copy, cents. Cable Address, ADVERTISING STAFF Emerson Findley, €21 Union Bidg., Cleveland 6. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia. Pa. H. K. Hottenstein, 862 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 1310 Woodward Ave.. Detroit C. H. Ober, 239 W. 39th St.. New York W. B. Robinson, 428 Park Bidg., Pittsburgn D. C. Warren. P. 0. Box 81, Hartford. Coan RON AGt SEPTEMBER 30, 1937 Salesman Knudsen Industry Has Been Made Whipping Boy Gas Hot-Tubes for Burning Porcelain Enamel Jovignot's Cupping Test for Sheet Metal Control Materials Handling Systems Cleaning for Hot Dip Galvanizing and Federal Shipbuilding Builds Caisson for Lincoln Tunnel. Automotive Industry Statistics Metal-Working Washington News ....... Plant Expansion and Equipment Buying New Industrial Literature Just Between Two Products Advertised Index Advertisers Copyright 1937 Chilton Company 104 106 130 — | | if if q Ss steel every shape and size standard and alloy grades stock for Immediate Shipment. Allied lines such welding rod, babbitt, boiler tubes, tings are also carried. Shears, saws and special flame cutting equipment quickly cut any length special shape. Whatever your requirements you can call Ryerson with full assurance that everything possible will done deliver the material well within the time specified. Ten plants stand ready serve you. Draw the nearest one. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cleveland, Cincinnati, Buffalo, Boston, Philadelphia, Jersey City | | — THE IRON AGE... September 30, 1937 ESTABLISHED Vol. 140, No. Salesman Detroit last week came bit news that interest all who have been following the unsettled course employer-employee relations this country. This contained the text resolution issued the executive committee the Automobile Union answer William demand for assur- ance against the strikes which have frequently interrupted General operations since the signing the agreement with the union. The resolution referred read follows: Union agrees that the responsibility the Management maintain discipline and efficiency its shops, and the right the employer hire, discip- line and discharge employees for cause expressly recognized, subject the right appeal through the Grievance Procedure. Union recognizes and agrees that unauthorized strikes, stoppages work, and deliberate reduction rate production below standards established accord- ing Section the agreement, before all the steps set forth the Grievance Procedure have been complied with, are indefensible and for violation this pro- vision the Union, its officials members, the Company will discharge otherwise discipline the employee employees known found guilty thereof, and the Union shall take effective disciplinary action against the member members the Union responsible therefor. the part the Union with the above provisions shall deemed breach the agreement and just cause for immediate suspension cancellation thereof the Company.” The employer who signs contract, either from free will through compul- sion, usually does hope and fear. hopes that the arrangement will work out, through enlightened leadership both sides, the satisfaction both parties. fears, however, that unless such exceptional leadership may develop, mass organization, its may attempt curtail those functions management which are necessary for the preservation production efficiency. also fears that spontaneous and unauthorized strikes, the case the motor industry, may break out any time spite the written contract. The UAW resolution sets precedent recognition rights and labor's obligations these matters. also provides positive prevention for strikes, either the any other variety. Credit due Homer Martin and his executive board for accepting this enlight- ened viewpoint and even more credit, think, due Mr. Knudsen, for them the idea. if j i if i J { KULAS INDUSTRY, seems, has now been promoted the post whipping boy national politics. Once, within the memory some who not consider ourselves old, was railroads. Then was oil which furnished the “robber barons.” Much more recently, memory not playing tricks, heard lot about the money changers. But now industry. dustry must not allowed make profits and hold any part them for rainy day. taking the money away from industry are going make everybody happy. Quite evidently there must something wrong about this indus- trial system which have devel- oped this country. They tell down the street corners, well some higher places, that has been making the rich richer and the poor poorer. That may make you wonder where all the low priced automobiles and radios and other products industry have been going. The rich must getting pretty well stocked up, be- cause there have been lot them sold. true that industry, which constantly the alert for better ways doing things and for ma- IRON AGE, September 30, 1937 ndustry Has KULAS President Otis Steel Co., Cleveland chines which extend the work men’s hands that greater pro- duction can obtained, adding the wealth those who have and depriving those who have not, then will all agree that there something wrong. But that true? are those who are busy their efforts promote dissatisfaction and unrest actuated motives which are sinister just plain selfish rather than the sympathy they pretend for the worker? There are some statistics which bear the question which have not seen generally quoted. Unfor- like golf players, not always follow through. They have irritating way taking different point approach for each study, that figures for one group years are not comparable basis with those for another. Still there are comparable figures cast con- siderable light the question, ene really wants the truth. More National Income Goes Labor There is, for instance, break- down the national income for few recent years, made the Fed- eral Department Commerce and rublished that department’s Statistical Abstract. This throws unexpected light the depres- sion years. gives the total na- income for 1929 $78,632,- 000,000. That total broken down into four subdivisions, salary and wages, dividends and interest, rents and royalties and “entrepreneurial withdrawals,” which assume means management and promo- tional profits. The which are the income ownership, totaled $27,145,000,000, while wages and salaries, the income employees, totaled $50,487,000,000. percentages the share em- ployees was 65.5 and that own- ership 34.5. For the year 1935, after five full years depression, the total national income had dropped $53,578,000,000. That part which went ownership amounted $17,530,000,000, while the share going employees wages and salaries was $36,048,000,000. Quite surprisingly the share paid em- ployees, notwithstanding the wide- spread unemployment and wage cuts, had risen 67.3 per cent the whole while the share going ownership had dropped 32.7 per cent. The years covered this rather startling change were depression years, when might argued | ; | | | ° ° | | ‘ | Whipping Boy National Politics that almost anything could ex- therefore, that the trend chang- ing ratio between ownership and employees was not different from that preceding years. The De- partment Commerce only com- menced its breakdown national income with 1929, figures from previous years are not obtainable from the same source. But Wil- ford King, recognized au- thority, his book “The Na- and Its Purchasing Power,” gives figures for number years and including 1928, which show that the share the employees has been steadily in- creasing for some years. 1914, according Mr. King, owners received 48.06 per cent the national income and employees 51.94 per cent. 1920 the share the owners had dropped 46.32 per cent and that the employees had risen 53.68 per cent, while 1928 the owners got but 42.83 per cent and the employees 57.17 per cent. The two groupings figures are not the same basis and neither percentages nor dollar to- tals agree. Their significance lies the fact that they agree exactly the trend the division between owners employees. Mechanical Production Has Not Reduced Share Output Years for which these two sets figures with their identical trends apply were years which saw great development the kind for which American industry criticised superficial critics—the development mechanical aids production. The record machin- ery used found the record power consumed manufacturing. Figures the Census Bureau give the power consumption 1914 22,290,899 hp. For 1919 the figure was 29,327,669 and for 1929 was 42,931,061. Power consumption, which means mechanical develop- ment, almost doubled the years from 1914 i929. Those were the same years which the share the national in- come going employees increased from 51.94 per cent 57.17 per cent and the share going owner- ship decreased from 48.06 per cent 42.83. those same years the dollar total paid wages industrial workers, this time not including salaries, went from $12,396,000,000 1914 $32,235,000,000 1928, according Mr. King’s statistics. little less than double the ma- chinery, measured the con- sumption horsepower, produced considerably more than two and half times the wages for workers, while producing smaller propor- tionate dollar volume and low- ered share total income for the owners. One specific illustration what has been happening furnished the steel industry. Figures gathered the American Iron and Steel Institute show that 1918 payrolls took out each dol- lar gross sales. 1929 the figure was 37c. and the depres- sion years 1930 1935 was Since wage rates and num- bers employed have risen faster than sales prices the present recovery, the payroll share the sales dollar would still higher now. Employment Some Industries Greater Than Ever Before Definite figures the numbers persons employed industry are not reliable figures wages and incomes. There has always Mr. Kulas Says: those who are busy their efforts pro- mote dissatisfaction and un- rest actuated motives which are sinister just plain selfish rather than the sym- pathy they pretend for the worker? ANY those who dis- cuss industrial prob- industry through the wrong When look manufac- turing industry honestly find that component part our whole structure its effect every other phase life. does not yet seem have dawned many labor specialists that the limit wages which can paid for particular industrial operation given time not set the selfishness cruel employer but the level which cost pro- duction can raised with- out checking consumption. happy fact that the mechanical development industrial processes has benefited the world large and the same time the worker HETHER yet recog- nize it, more less permanent pattern for Amer- ican industry has been emerg- the intelligent use power the industrial work- who will profit propor- tion the important service renders the public. THE IRON AGE, September 30, | | | | it it i H | i Hila j rit 4 | i 5 been fuzzy character about em- ployment statistics and Govern- ment, least all the one have now, seems want know how many are employed and how many are idle. know that employ- ment some specific industries, which the steel business one, greater than ever history, and from general figures industrial production can only assume that the same true through pretty well all industry. But actual employment men and women the industrial arts does not and never has included anywhere near all the men and women employed because indus- try. illustration have seen the development within recent years mighty rayon industry, one the marked effects which has been replace our domestic markets vast quantity im- ported silks with material domestic manufacture. would not know how many thousands men and women have been given direct employment this thriving new industry. know, however, that those who and out the rayon are but part those whom the industry has given em- ployment. The natural materials have raised and handled and shipped and the finished product swells the distribution task clear down the retail counter over which passed the ultimate consumer, often far from any in- dustrial producing center. Manufacturing Industry Toughes Every Phase National Life Many those who discuss in- dustrial problems, including, fear, some who ought and possibly know better, insist looking industry through the wrong end the telescope. They set manufac- turing apart activity itself which should dealt with sep- arately from the rest our con- cerns when actually every single element our food, clothing and shelter, every article our con- sumption use has pass through manufacturing stage be- fore comes us. have lost our taste for raw meat have become civilized and takes bil- lion dollar packing business pre- pare for us. Our grains must milled, our vegetables least cleaned, graded and shipped, our wool carded and our cotton woven. When look the manufac- turing industry honestly find that component part our 20—THE IRON AGE, September 30, whole structure modern life, af- fected every condition which affects any other our many ac- tivities and turn having its effect every other phase life. Prairie Gulch, there any such town, out the edge things, may feel that has little interest industrial problems industrial advancement. But the modern motor car factory with its thou- sands employees producing mil- lions dollars worth merchan- dise well plenty industrial headaches, had not been evolved the development industrial sci- ence, the two three filling sta- tions and the repair garage which are important the life Prairie Gulch would not exist. the packers and the canners and the textile mills and the makers household gadgets did not provide for the needs all, Prairie Gulch would not even exist. Mechanization Has Reduced Cost and Prices Steel has taken some the owners industry long time realize the social significance their ac- tivity and recognize that pay- roll dollar, before gets through rolling, will have created many market dollars keep their ma- chines turning. Similarly does not yet seem have dawned many labor specialists, least all those who specialize labor for political purposes, that the limit wages which can paid for par- ticular industrial operation given time not set the selfish- ness cruel employer but the level which cost production can raised without checking con- sumption. What known mechanization industry, which meant the introduction mechanical devices which extend the work men’s hands that the production per man largely increased, has been re- garded more less private quarrel between owner and em- ployee. But has its public side which fully important. New devices which have increased pro- duction greatly have, course, held down prices and spurred sales. They also have made for greater uniformity quality which has had great effect the creat- ing entirely new markets. One the best illustrations this found the steel business. Sheet steel today costs about half much did before the intro- duction the continuous rolling mill. addition the continuous because they roll large quantity sheets such short time that reheating not neces- sary, have produced much greater uniformity quality. conse- quence sheet steel can now used for many articles for which was not suitable before. Steel may seem commod- ity interesting principally terri- tories like Ohio and western Penn- sylvania, where the bulk the production had and where the question how many men are em- ployed and what wage prime importance. But every little town and country crossroads settle- ment vitally interested are the steel country. Some the new markets created have been the mass production radios and refrigerators which never had before, the production better and cheaper automobiles, even better and cheaper tin cans. That the nationally public side what sometimes represented pure- industrial problem. narrow way would more than fair say that the interest the man who actually works industry only part and not the larger part the interest involved industrial advancement. the men who actually work indus- trial production were better off than their fathers, who worked ex- clusively with their hands, could still say that our industrial development has been entirely jus- tified because its great contribu- tion the development the whole country and its people. Real Wages Have Moved Through Mechanical Development Fortunately not have make such choice between the interests the industrial worker and the rest the country. Sta- tistics show conclusively that mechanical development Ameri- can industry has progressed there have been three movements which have kept steady pace with it. Wages have gone up, hours labor and the requirements for great physical exertion have gone down and also have the prices which the products industry can purchased. That wages have moved while prices were moving down amply shown cost living study the National Industrial Conference y | | | i! i Board, which shows that auto- mobile which would have cost the wage worker 3081.7 hours labor 1914 could earned 859 hours 1936; that pair work shoes which would have cost him 9.3 hours work 1914 cost but 3.4 hours 1936 hat which cost 11.5 hours his time 1914 could had working 3.4 hours These are but few the examples cited the study. happy fact that the me- chanical development industrial processes has benefited the world large and the same time the worker industry. think this because most our mechanical de- velopment has been along semi- Forging Machines National Machinery Co., Ohio, has just shipped two high-duty forging machines which are much larger than any such machines heretofore They are intended for upsetting operations tubing, and will han- diameter. These machines follow the stand- ard design National forging machines manufactured this company, and have massive un- derslung bed frame; suspended automatic rather than fully matic lines. Completely automatic machinery pre-supposes very large production completely identical articles. other basis could considered economically sound. But spite all the talk about our genius for mass production the American people will not put their buying into groove. More than any other people earth they are imbued with that restless spirit which demands constant improve- ment. They are always ready throw away trade this year’s gadget next year’s design has greater beauty, more utility promises better service. Our semi-automatic machinery, over-arm type heading and gripping slides; longitudinal and cross tie bars for added rigidity, and air- operated friction clutch. Some idea the size the machine can gained calling attention the fact that the bed frame made two sections, each which large can shipped. The ma- chine assembled location, and the bed held together enormous tie bars shrunk place. further idea its size can gained mentioning that the stroke the heading ram in., and the ma- where power furnishes the brute strength and man furnishes the judgment and skill, retains the flexibility which permits the con- stant change the American market demands. Basic principles manufacture may remain the same but the individuality each design accomplished. suspect that whether yet recognize more less perma- nent pattern for American indus- try has been emerging during these years development, pattern based the intelligent use pow- the industrial worker who will profit proportion the im- portant service renders the public. chine uses gripping dies in. long. The weight this ma- chine 500,000 Ib., and required 150-hp. motor drive it. One view showing the machine finished the shop gives some idea its enormous size. The other view shows that dozen men can stand the die box space. Forging machines have become highly important master tool in- dustry, and with their broadened range and capacity their service- ability becomes more extended. THE IRON AGE, September 30, 1937—2! | j i ia by a { ; | j | | Chemical Kettles many different ways. This greater extent than realized the cause failure success their production. Seldom enough thought given the reactions that take place when the mold filled and the metal still the molten state— and sometimes after has solidi- fied. the casting comes out the mold with smooth surface, true pattern, and checks with the desired analysis, most foundrymen are satisfied that they have done good job. However, has been demonstrated that more careful study mold conditions, mold materials, and molding methods, improve the quality and prolong the life the kettle very mate- rially. kettle castings are molded PAUL RAMP The dry sand mold used some, using sweep shape the mold. The result irregularly rammed surface that produces nu- merous different thicknesses metal throughout the entire cast- ing. Though small, these variations are numerous and set minor in- ternal strains that may scoffed many veterans but neverthe- less they shorten the life cast- ing subjected hard service. The ramming these dry sand molds conjunction with the sweep method cannot uniform, and many places that are rammed too hard create spots the mold that cause undesirable agitation even the extent producing plate scab cut the surface the mold. Such practice also produces metal with sand particles mixed the chemicals and heat. These sand particles may not dis- covered the surface, but they are there and eventually show service with some very expensive results. These are but two the im- portant reasons why dry sand “swept-up” kettle mold not the correct mold produce high grade casting. Making kettle molds using cast iron prickered brick with per- forations the brick for vents and covering the brick with coat loam would appear good method, especially from nomic point view, were not for the rapid cooling the metal sec- tion drag mold showing sweep and spindle. i base 22—THE IRON AGE, September 30, 1937 caused the absorption the heat the metal brick. This has semi-chilling effect the cast- ing, causing the development small checks cracks which event- ually break down the metal struc- ture and shorten the life the kettle. The method using the same mold surface several times, care- fully lifting the casting out the mold cheap but very unreliable and always results dirty metal even though the surface the casting may appear good. The gating these kettle molds many times error. Gating from the top with pencil gates almost standard practice and would correct the plan did not de- posit the first iron that enters the bottom the casting and allow remain there the very point where the best metal required. The plan molding the kettle bottom because the bottom twice heavy the side—the thought being, “it easier feed the heavy bottom” mistake, will not produce good casting. Method Gating and Pouring Important The method gating and pour- ing highly alloyed kettle pot castings has great influence their life service. When molten metal comes contact with the surface mold agitation created that affects the quality the metal. This agi- tation may hardly noticeable but can have damaging effect the quality highly alloyed iron. advisable, therefore, direct the flow the metal manner that will eliminate this agitation before solidification takes place. The first metal that covers vital portion mold must not allowed remain that point, but after has served its purpose preheater and cleanser, must pushed along less im- portant location the mold. This more important the production alloy castings than without alloys because metals containing high percent- age alloys are more sensitive mold conditions than ordinary iron. The material used make these molds itself the life the casting. material that pro- duces smooth casting does not always produce sound casting, casting that will stand service when subjected the ac- tion chemicals heat, even though may contain the specified percentage alloys. has been found that the production high grade chemical castings some the molding methods and mold- ing materials used years ago are decided value today. With this mind are de- the method molding shortcomings vari- ous methods molding large kettle castings are out- lined this article, and method that has been found produce high-grade alloy castings that will stand hard service described. kettle casting, which may appear kindergarten work many, but most reliable method molding produce high grade alloy casting that will stand service. drag part 12-ton kettle mold, with the sweep position, the brick work completed, and the loam applied the brick swept the desired shape form the outside the casting. The gates leading from the joint the bottom the mold shown are formed the use dry sand cores made lengths that enable the molder build the gate the same time the bricks are being laid. Spindle ~ This completes the work mak- ing the drag mold. The next operation reduce the size the sweep will form the inside dimension the kettle. This accomplished removing thickness strip false edge that has been attached the sweep, form the greater outside diameter the mold. The method used secure the desired thick- ness the kettle follows: Twenty strips made wood that conform the shape the out- side the kettle one side, and the inside the other edge, are placed the drag mold equally spaced. The spaces between these thickness strips are filled with black sand, “which properly tem- pered molding sand,” the sweep again used sweep the surface the black sand the required size and shape. This done, the sweep and spindle are removed and the mold ready for the crown plate. The crown plate real- ity the lifting plate that carries the part the mold which forms the inside the kettle. crown plate just completed and ready for drying. The crown plate proper consists heavy plate with long prickers carrying-rods cast it. The carrying-rods shown Fig. are used carry the brick employed making this part the mold. Numerous holes marked “vents” are also cast the plate order provide escape for the gas generated when the mold filled with metal. The bricks are held place means small metal wedges Fis. 2—Cross section completed crown plate with sweep position. THE IRON AGE, September 30, | | il | | 4 Gas Hot Tubes for Porcelain Enamel porcelain enamel the deluxe for iron steel has received added impetus through the fair- recent introduction the ible gas radiant hot tube type furnace which has materially reduced the cost this finish. the basic principle tained heating unit, consisting tube heated from the inside gas burner, almost any type furnace can easily equipped with this method heating. Fur- thermore practically all kinds furnaces including the box type, hairpin type the long continuous type, can converted this new method heating quickly and easily. All that necessary re- moye the existing gas burners SPRAY BOOTHS INTERCHANGER view continuous gas-fired porcelain enameling furnace 26—THE IRON AGE, September 30, 1937 PREHEAT NEALEY American Gas Association ° ° heating system refractory muffle and install the gas radiant tubes. These hot tubes are alloy steel and are applicable with tempera- tures 1800 deg. prac- tically any atmosphere. The gas radiant tubes are varying lengths and diameters and lie within the furnace with one both ends protruding through the furnace wall. gas burner fires into one end and the hot products combustion, after passing through the tubes, are discharged the atmosphere and outside the furnace. other words the hot CONVE products combustion can enter the furnace. Flexibility operation one the advantages the versatile gas hot tube. furnace equipped can closed down will and with impunity and addition has quick recovery. The saving cost fuel when porcelain enameling furnace can shut down nights and weekends very material. such operating schedule should addition, maintenance the muffle, plus the rapid deterioration the refractory hearth due the severe fluxing action enamel from the ware dropping it, are elim- inated. Naturally the first vitreous enamel furnaces employed this country were the batch type. They had and were heated BRUSHING UNITS showing layout spray booths, dryers and brushing units. i} COOLING HEAT HOT PREHEAT HEAT HEAT HOT HEAT COOLING Front end porcelain enameling vitrifying and drying oven, showing conveyors and dipping tank. with coal burned fire boxes. Discoloration the ware the sulphur the coal neces- sitated its protection Furnaces heated with oil gas made their appearance the turn the century but the need for the muffle remained. Semi-muffle and then intermittent furnaces without muffle were introduced with little improvement atmosphere control otherwise. This intermittent type was operated firing the furnace until the entire brick shell was heated, when the gas burners were turned off, the atmosphere purged and the ware put and burned the residual heat given off the brick. The full furnace finally became standard and the first real improvement came with the invention the high tempera- ture refractories, silica carbide and fused alumina. These soon replaced fire clay muffle construction, because their greater mechanical strength, greater thermal conduc- tivity and ability withstand higher temperatures. other words, thinner sections could used the muffle wall which in- creased the heat transfer and con- sequently the productive capacity the furnace. With mass production came the semi-continuous and continuous enameling ‘furnaces, the circular and straight through types and finally the hairpin furnace. Eco- nomical and flexible gas became extensively used fuel. Hearth con- veyors were replaced the chain suspension type conveyor which the work hung tools (inside the furnace) suspended from moving chains, above and out- side the furnace with the shanks the tools traveling through slot the rear the furnace. One the best designs for the straight through chain suspension type uses the counter-flow prin- ciple heating which permits the view furnace showing location tubes, together with burner and eductor. THE IRON AGE, September 30, 1937—27 ii Covering plate Prickers ring, hole between the bricks and the carrying-rods. When these bricks haye been properly secured coat loam applied and the sweep used shape the inside bottom the kettle. While building the brick, the space between the brick and the heavy metal plate filled with cinders, which provide for prompt escape for the gas. After the mold has been formed the crown plate described, the sweep and spindle are removed, the mold given coat blacking and placed After the crown plate dry enough handle without the loam falling off removed from the oven, turned over and placed the bottom the drag mold, allowing rest upon the thickness strips and the black sand. fits prop- erly the next procedure build the balance the inside mold base the kettle with brick and loam until the level the joint the mold reached. This done the usual manner loam molding with pattern. The black sand and the thickness strips represent the pattern. The next operation provide lifting ring cope, which ring used carry the inside part the mold. Fig. cross section the lifting ring the making. Prickers are provided carry the loam the surface that will come contact with the drag mold and form the top the flange. this case the loam used very dry and rammed the plate and struck off level with the sweep. The sweep shown Fig. The lifting ring mold finished and dried, then turned over and placed upon the molds and properly se- cured the center core heavy Black sand Crown Fic. 4—Cross section kettle mold ready for lifting off the cope. 24—THE AGE, September 30, 1937 1G. Sketch showing lifting ring the making. hooks that fit into loops cast the crown plates for that purpose. Fig. cross section the kettle mold ready for the cope lifted off, shows the result all the work previously described. The mold built upon heavy bottom plate that used binder conjunction with the lifting ring when the mold being poured. The position the crown plate, part the mold, shown with the continuation the brick wall that has been built above it. One half the cross section shows the thickness strips and the other half the black-sand thickness. The lifting hooks that extend through the lifting ring and con- nect with the loops the crown plate carry the entire weight the inside core the mold. The stool posts are used help resist the lifting pressure that exerted against the core when the mold full molten metal. The next procedure lift out the center part the This done attaching heavy slings the lifting lugs the lifting ring. After the cope has been lifted off the black sand and thickness strips are removed and the surfaces both drag molds are finished, blacked, and thoroughly dried. ton chemical kettle mold ready for pouring. This mold poured with two ladles order secure better distribution the metal and bet- ter direct the flow same. Note the two pouring basins and the gates leading from these basins the bottom the mold. This plan gating forces the first metal rise | | | wee, | j | | | | -Basin sand Lifting plate plate the top the mold after has flowed over the bottom surface, which heats the bottom and per- mits the final metal lie quietly without any agitation this point. The tie-bolts areshown that extend through the lifting ring and the bot- tom plate and bind the mold to- gether. The mold made pit make pouring easy and held together ramming sand firmly between the outside the brick walls and the usual steel curbing. Additional weights are used shown; they extend over the mold far enough permit them being supported the foundry floor. prevent their weight from crushing the mold, after the weights have been placed with 2-in. space between their lower surface and the top the lifting ring, metal wedges are driv- between the weights and the lifting ring. This sufficient weight hold the cope down with- out any danger crushing the mold. The risers flow-offs are shown extending through the lifting ring. The mold made loam this manner assures mold with uni- form hardness surface, that pro- duces casting uniform thick- ness and mold surface which will not cause any agitation the metal. Porcelain Enamel Used For Exterior Office Building beauty and adaptability modern porcelain enamels are typified this photograph the new office building Davidson Enamel Products Co., Inc., Lima, Ohio. The building, designed Douglas Andrew, shows the wide variety finishes colors available for architectural uses. The window course light tan with snap-on moldings and the area about the doorway ivory. The coping tan and chocolate. Two decorative plaques, showing char- acteristic views enameling op- erations, are mounted the side the entrance-way. Pan and semi- pan parts, with Armco 16-gage enameling iron the base, are used the exterior. THE IRON AGE, September 30, | = { | ; | 4 | - Gas Hot Tubes for Porcelain Enamel porcelain enamel the finish deluxe for iron and steel has received added impetus through the fair- recent introduction the flex- ible gas radiant hot tube type furnace which has materially reduced the cost this finish. the basic principle tained heating unit, consisting tube heated from the inside gas burner, almost any type furnace can easily equipped with this method heating. Fur- thermore practically all kinds furnaces including the box type, hairpin type the long continuous type, can converted this new method heating quickly and easily. All that necessary re- moye the existing gas burners SPRAY BOOTHS COOLING PREHEAT NEALEY American Gas Association heating system refractory muffle and install the gas radiant tubes. These hot tubes are alloy steel and are applicable with tempera- tures 1800 deg. prac- tically any atmosphere. The gas radiant tubes are varying lengths and diameters and lie within the furnace with one both ends protruding through the furnace wall. gas burner fires into one end and the hot products combustion, after passing through the tubes, are discharged the atmosphere and outside the furnace. other words the hot CONVE urning products combustion can enter the furnace. Flexibility operation one the advantages the versatile gas hot tube. furnace equipped can closed down will and with impunity and addition has quick recovery. The saving cost fuel when porcelain enameling furnace can shut down nights and weekends very material. such operating schedule should addition, maintenance the muffle, plus the rapid deterioration the refractory hearth due the severe fluxing action enamel from the ware dropping it, are elim- inated. Naturally the first vitreous enamel furnaces employed this country were the batch type. They had and were heated BRUSHING UNITS view continuous gas-fired porcelain enameling furnace showing layout spray booths, dryers and brushing units. 26—THE IRON AGE, September 30, 1937 | HEAT HOT PREHEAT HEAT t j ‘ q Front end porcelain enameling vitrifying and drying oven, showing conveyors and dipping with coal burned separate fire boxes. Discoloration the ware the sulphur the coal neces- sitated its protection muffle. Furnaces heated with oil gas made their appearance the turn the century but the need for the muffle remained. Semi-muffle and then intermittent furnaces without muffle were introduced with little improvement atmosphere control otherwise. This intermittent type was operated firing the furnace until the entire brick shell was heated, when the gas burners were turned off, the atmosphere purged and the ware put and burned the residual heat given off the brick. The full muffle furnace finally became standard and the first real improvement muffles came with the invention the high tempera- ture refractories, silica carbide and fused alumina. These soon replaced fire clay muffle construction, because their greater mechanical strength, greater thermal conduc- tivity and ability withstand higher temperatures. other words, thinner sections could used the muffle wall which in- creased the heat transfer and con- sequently the productive capacity the furnace. With mass production came the semi-continuous enameling the circular and straight through types and finally the hairpin furnace. Eco- nomical and flexible gas became extensively used fuel. Hearth con- veyors were replaced the chain suspension type conveyor which the work hung tools (inside the furnace) suspended from moving chains, above and out- side the furnace with the shanks the tools traveling through slot the rear the furnace. One the best designs for the straight through chain suspension type uses the counter-flow prin- ciple heating which permits the view furnace showing location tubes, together with gas burner and eductor. THE IRON AGE, September 30, il iit if 17 radiant tube furnace recent design, for porcelain enameling. application and finishing two coats before removing the ware from the conveyor. The closed loop chain conveyor located that the tools pass along parallel slots the roof. Thus two lines work are continually passing through the furnace but opposite directions. The first coat applied and the work hung the con- veyor one end and burned passes through, the second coat sprayed the conveyor makes the turn the opposite end, and this burned turn the conveyor makes the return trip through the furnace. The hot zone the center the furnace that the incoming cold work pre- heated the hot outgoing ware both ends and this known the counter-flow principle. The great- est difficulty atmosphere and temperature control, for tunnel, open both ends, subject through drafts. With view improving this, the hairpin type was designed which like the one described, but with one end closed and the hot zone placed that end. The counter- flow principle also holds with this type furnace. The hot zone and the hot products combustion are carried under the hearth the preheat section augment the heat interchange furnished the outgoing hot-ware the incoming cold work. dis- 28—THE IRON AGE, September 30, 1937 tinct improvement porcelain enameling practice, accomplished with these two types furnaces, the slow heating and cooling which materially betters the ware. number variations the above types have been tried, some with success. for any reason this newly de- veloped gas hot tube type fur- nace not enmployed, the opera- ting costs all these other various types enameling furnaces, just described, can materially low- and the maintenance costs practically eliminated applying gas hot tubes them. already stated, all that necessary make this conversion pull out the muffle and existing burners, grids and ribbons the case may be, and install the easy-to-handle gas hot tubes. There always plenty space between the ware and furnace walls floor for this. each tube separate unit itself, gas burner and all, the cor- rect number can selected and the hot tubes spaced pro- vide any heat condition required. Furnaces which are installed hot tubes almost 100 ft. length, are use today. Absolutely even distribution heat one the features these gas hot tubes. Placing the heat where most needed, the bottom, another. With the con- tinuous type furnace the length the unit and the speed the conveyor are varied correctly regulate the preheating, heating, and cooling periods. Automatic temperature controls maintain the desired temperature, regardless changes the volume work going through. capitulate— economical gas hot tubes supply the long needed flexibility, and re- duce operating and maintenance costs very materially. BURNER EXHAUSTS BRICK SUPPORT FOR Cross section the radiant tube furnace shown elevation above. Cupping Test for eet Meta ° PAUL BASTIEN the first section this article, which appeared Sept. issue, Mr. Bastien discussed the structural and operating characteristics Jovignot's fluid pressure machine for testing sheet metal. The advan- tages machine were pointed out and the criticisms which have been directed were analyzed. this, the concluding article, the results fluid pressure cupping tests are compared with tests made machines employing the cupping medium. Mr. original article appeared Revue Paris, and reproduced here through the courtesy Sheet Metal Industries, London. GOUGH and Hankins compared the stress fracture, calculated indicated the first part this article means the formula for the strength thin spherical shell, with the breaking load for the same metal subjected static tensile test. The comparison was made for nu- merous metals (brass, copper, tin plate, mild steel, aircraft steel, stainless steel, zinc, aluminum and cupro-nickel) and for different thicknesses. the majority cases, the ratio the two break- *Guillery. Bull. Soc. Enc. Ind. Nat. ver ngineerin 497 (1914). ing loads remains very satisfac- torily the neighborhood unity. (See Table II). The fluid-pressure cupping test thus capable rendering valu- able services regard the de- termination the breaking loads sheet metal. The test rapid and does not necessitate any pre- piece. the National Physical Laboratory, the method has been found particularly useful for determining the tensile strength very thin metal foils, for which generally very difficult make correct tensile test. Before terminating this review, there are two points the investigations made Gough and Hankins which are interest. With the N.P.L. machine de- scribed the previous article, possible record the pressure- diagram the spherical segment while test progress. According the authors, this di- agram recorded the point fracture ought provide useful basis for deciding whether metal suitable for cold drawing. The recorded curves have marked re- semblance the load-extension diagrams recorded tensile tests. Gough and Hankins endeavored define the suitability metal for cold drawing from com- plete cupping diagrams. These tests, applied certain number pressing metals, were not con- clusive all cases, but they have led the authors believe that such diagrams permit better choice made between the various metals than the knowledge the ultimate stress alone and the cupping co- efficient given the fluid-pres- sure cupping test without record- ing. Diagrams the deformation under tensile stress recorded along and across the metal probably fur- nish similar information, but THE IRON AGE, September 30, ry | { | . a j is 4 | iF 1 LL type tests. tests. NJ Fic. 10—Form tool used tests. reasonable suppose that the cup- ping diagram can obtained more easily and rapidly and has ad- dition the advantage furnishing single test information regard- ing the directional “surface” prop- erties the test-piece. With view completing the investigations reviewed the pre- vious article, Gough and Hankins Type Persoz RIGHT son cupping Elongation, per cent, coefficient cupping per cent, Depth cupping mm. for the Perso tests mild steel. 100 RIGHT 12—Compari- son cupping tests copper steel. o ion, per breaking load,ka.per sq.mm Depth cupping mm. for the Persoz test circular elongati made comparison between the oil-pressure cupping test and the Guillery, Erichsen, Avery, A.E.G. and K.W.I. methods employing tool. The and Erich- machines are all the same type and utilize the method per- fected Persoz long ago 1903 (Fig. 8). They employ tool TABLE Il. Relationship Between the Tensile and Jovignot Tests Metal Tested 30—THE IRON AGE, September 30, 1937 Jovignot Test Value the Ratio Tensile Test 1.03 0.88 1.08 (according thickness) 0.98 1.19 (according thickness) 0.96 0.86 0.87 0.95 (according thickness) 0.95 0.98 (according thickness) 1.0 Thickness sheet, mm. having spherical tip mm. diameter. These machines merely differ details concerning the shape and diameter the clamp- ing dies. The A.E.G. test differs from the preceding methods the shape the cupping tool which cylindrical with rounded edge (Fig. 9). The K.W.I. method evolved Siebel and Pomp the Kaiser-Wilhelm Institute employs cylindrical tool having rounded edge similar the A.E.G. tool, acting test-piece with 12- mm. diameter hole drilled the (Fig. 10). The comparisons were made from the point view ductility comparing the percentage values the Jovignot cupping coefficient with the circular elongation the hole the K.W.I. test and the de- the Erichsen, Guillery and A.E.G. tests. For some metals. | NJ | afion x 4 Tensile elongation the elongation fracture the tensile test was also considered. The curves shown Figs. 11, and relate four types mild steel, copper soft alumin- ium, tested for various thicknesses. will noticed that, taken altogether, the different curves have the same shape. inter- esting that the range the values found—that say, the sensitiv- ity—is the greatest the tests and, lesser degree, also the Jovignot test—a point favor these two methods. conclusion, the investigations which have just been reviewed ap- pear show that although the present position the problem may not possible draw defi- nite conclusions regarding the suit- ability sheet metal for indus- trial cold pressing and drawing from the results cupping tests, even carried out means oil pressure, yet the Jovignot method test- ing places the disposal the sheet metal industry simple and rapid method testing which produces cup known geometrical shape, eliminates the effect fric- tion and the surface con- dition the edge the test-piece and provides measure the surface de- formability the metal. This group properties al- lows one conclude with Gough and Hankins that the fluid-pressure merits the attention engi- neers and ought made the subject thorough investigations Jovignot cupping coefficient, per cent, circular elongation, per cent, Japans Tin Plate Hold Despite Domestic Output Increase OKYO (Special Correspon- into Japan remain relatively stable over the past nine years de- spite sharp increase domestic production, Government figures show. During that period the smaller firms slowly gained ground against Yawata, largest producer and prices for this product are fixed monthly meetings. Japan Iron Mfg. Co. (capital 359,812,000) the largest all tin plate manufacturers the country. The company’s tin plate work done Yawata. the only plant where done continuous process from the ore. The company’s production dates from the year 1923. The output and imports recent years, ac- cording official statistics, are below, the figures being tons: Production Imports 94,920 The appreciable increase pro- duction indicated for 1934 due mostly the contributions which those other than the Japan Iron Mfg. Co. began make. The pro- duction since then major manu- factures are follows: (The fig- ures are metric tons.) 1934 Yawata Iron Works. 55,230 84,808 100,237 Fuso Kogyo (Steel). 5,931 6,160 13,768 Toyo (iron Iron Sheet Section .... a dae 446 2,348 Yawata’s position predominant. Its product directly supplied large consumers such the mili- tary and official establishments, petroleum companies, etc. Market- ing done through Mitsui Bussan, Mitsubishi Shoji, Iwai Shoten, Ata- Shoten. Toyo Kohan (capital lion), O