The Iron Age 1937-11-04: Vol 140 Iss 19

j new ond mprovec Giloy ond cordon stee Ss, perfected sic heot-resisting steels, mechanically perfect electric weld pipe, casing ond other standard and specia REPUBLIC CLEVELAND, BRAND Amenable discipline machining, well behaved through all shop operations, ELEPHANT BRAND PHOSPHOR BRONZE PHOSPHOR BRONZE can worked easily ana quickly turned, bored, planed, tapered, hobbed, reamed, filed, drawn, ground, welded, cast, etc., with minimum effort, headache and cost. TOO TOUGH DESTROY Panty-waist? NO! This metal has guts that few others can equal. FREE Corrosion can't sap it; neither acid waters, corrosive fumes, mois- FREE REAMING ture can impair its long, useful life. Nor can tortuous treatment FREE FILING rob strength and toughness and natural elasticity. ELEPHANT GRINDING BRAND PHOSPHOR enduring for years applications FREE WELDING where formerly other metals required continual maintenance. REE CASTING recommended for just such spots and it's available the form you require and the correct alloy—for prompt delivery. STOCK AND PRICE LISTS, YOURS OBLIGATION = q a AS AMG A ao f fe,’ FREE TURNING FREE DED FREE TAPERING a q PHOSPHOR from all principal SILCROME STAINLESS STEEL metal working centers, backing eighteen strategically located Ludlum warehouses, are mill stocks and complete mill facilities 1/4 5,160 1-1/16 1,473 1/4” 115 ments both coasts. 5,943 1-1/8” 3,157 5/16” 421 3/8” 5,761 852 3/8” 235 ined for 1/2” 469 1/2” 336 tained for the convenience 6,073 1-3/8” 3,637 1,157 Ludlum customers are the accom- 5/8” 7,789 819 5/8” 307 11/16” 1,462 1-1/2” 2,591 3/4” 771 panying inventories Silcrome 5,681 1-5/8” 726 465 Finished, available subject 927 3,541 1-1/8” 536 3,371 331 Watervliet and Dunkirk, New York. Dunkirk close the rail center the country and permits direct water shipments all Great Lakes ports. Watervliet the heart the industrial East with prior sale. insure prompt shipment special sizes, large amounts hot rolled bars are also stocked the MILL STOCK 559 ROUNDS 1/4” 2,832 1,217 156 mill ready for cold finishing. Call Ludlum when your need 4,421 6,114 471 3,661 928 476 urgent. You will find organ- 6,153 1-3/8” 5,319 1,117 3,756 1,151 $73 ization experienced steel men 454 ready the limit for you— 1,251 3,218 1,553 5,826 1-3/4 2,335 1,327 whatever your problem may be. 1,518 1-7/8” 1,961 631 4,884 -15/16” 1,118 Watervliet, 6,631 SILCROME 12-EZ FINE STEELS SINCE 1854 THE IRON AGE, November THE IRON AGE, published every Thursday CHILTON CO. Publication Office, Chestnut 56th Sts., Philadelphia, Pa. Editorial and Executive Offices, 239 39th New York, Entered second class matter November 1932, the Office’ Philadelphia Act March 1879. year S., Canada $8.50, Foreign $12.00. Vol. 140, 19. wv | SILCROME 18-8-EZ a 1-1/4” 916 CHICAGO RAWHIDE MANUFACTURING CO. Years Quality Mechanical Leather Goods Exclusively PHILADELPHIA CLEVELAND NEW YORK DETROIT BOSTON 4—THE IRON AGE, November 1937 1306 ELSTON AVENUE CHICAGO, PITTSBURGH ILLINOIS CINCINNATI q your losses and let your profits ride” That was the entire philosophy one the most successful investors who ever lived. The same sound thinkingcan make money manufacturing almost every plant there equipment that somebody just bring himself junk— equipment that “seems good new” and still pro- ducing. Trouble is, may producing losses. Unless your equipment such accurate, easy operate the most modern the ket, you are not getting the profits which could yours. one hard-headed manu- facturer puts it, sell old turret lathes for anything can get. Let competitors lose money running them. new Wamer Swaseys will pay for themselves year, and put the strong posi- tion having the lowest pro- SWASE = supplied Cities Service Oil Company Nation- Wide Basis NEW CAR for Every Salesman and Not One Cent Invested Without investment, without the cost and annoyance repairs, your representa- tives can drive brand new cars, maintained perfect condition. Your men will cover more ground, more work, keep appointments more punc- tually, and make better impression for your company, when provided with first class transportation. Moreover, you will know advance the exact cost per month. YOU GET Cars replaced with new models every months. Fire, Theft and Collision insurance. All repairs and parts—mechanical those caused accident. All repairs and parts due collision. Replacement tires and repairs thereto. Oil, grease, towing and adjustments. Winter service. License plates. (For State where cars will operated. Replacement cars destroyed fire, collision otherwise. restrictions placed mileage use any all times. Decalcomania permitted. YOU PAY Only small flat monthly rate—regardless miles traveled. includes everything but gas, and your insurance. The maximum cost your transportation, operating under our plan, would not exceed per mile, everything included. Whether you operate one car fleet, this plan will save you money. Some our National Fleet users are The Vanadium Corp., Colgate-Palmolive-Peet, Cities Service, Herald Tribune, Philadelphia Daily News, Canada Dry Ginger Ale, Akron Beacon-Journal, Pittsburgh Post Gazette, Sayre Fisher Brick Co., etc. will pay you get full details. IRON AGE, November q | 4 | 4 | | 7 i i t | a — Pipe gets asphalt bath belt stands 5000 pounds pull typical example Goodrich improvement rubber OST belts turn pulleys. Loads are heavy, but motion usu- ally steady and one direction. The belt above had twist, stretch and turn, twice around the pipe, also around complicated system below it, revolving the pipe and pulling for- ward the same time. The pipe goes through machine long the belt stands this twisting and turning plus tension over 5000 pounds. clever, well-designed in- stallation except for one basic trouble: belt could found that would last more than two hours. Then plant engineers noticed that failure always started fasteners splices, decided try Goodrich Highflex belt with the newly devel- oped splice, splice that can- not open the seams because the seams are under the surface. The first Good- rich lasted days—nearly times the best record before. Technical development makes start- ling improvements, and Goodrich has applied such development every industrial rubber product. Modern Goodrich conveyor belts carry more tons than belts ever carried before; hose resists abrasive wear, sunlight, oils, chemical actions the various mate- rials handled; rolls and tank linings are made last almost indefinitely; new rubber products appear month after month, most them made fit cus- tomer’s special requirements and prob- lems. Somewhere your own plant the extra quality resulting from Good- rich research rubber can make saving today. The Goodrich Company, Mechanical Rubber Goods Division, Akron, Ohio. THE IRON AGE, November 4 4 if q 3 ~ YOUR LIGHTING MORE 22% more light yours from these modern light sources. They start instantly and hang horizontally give the best light dis- tribution. You save, addition, because you can run more lamps per circuit. The improved appearance has added the immedi- ate acceptance industry this improved lamp. Even the most difficult places you are assured ease seeing that profits both the worker and the manufacturer. These new “24-hour produce soft, non-fatiguing light that reveals detail promotes better work and reduces errors. There’s representative nearby who will glad give you complete information. will gladly survey your needs and tell you what modern Cooper Hewitt lighting can for you. you prefer, write directly the General Electric Vapor Lamp Com- pany, 833 Adams Street, Hoboken, New Jersey. GENERAL ELECTRIC VAPOR LAMP COMPANY 8—THE IRON AGE, 1937 LAR BUYS There glare from polished metal are easily detected eyes are rested and better work more easily accomplished with the than daylight” illumination the new horizontal Cooper Hewitts. | 7 y 4 iq 4 | q ' 7 = 4 oN /ORTH STEEL THE IRON AGE, November 4 TENS STEELS AMERICAN WIRE COMPANY, Cleveland, and New York CARNEGIE-ILLINOIS STEEL CORPORATION, Pittsburgh and COLUMBIA STEEL COMPANY, San Francisce NATIONAL TUBE COMPANY, Pittsburgh TENNESSEE COAL, IRON RAILROAD COMPANY, Birmingham United States Steel Products Company, New York, Export | ithe challenge years engineers and designers have said “Give steel that can afford pay—and will build our equipment lighter.” produced almost twice strong ordinary steel with times the resistance atmospheric corrosion with greater impact strength with superior fatigue resistance high abrasion resistance steel you can fabricate with little change shop practice steel that has made possible build mobile equip- ment 20—50% lighter just strong, just rug- ged the heavy construction replaces. And now, the one obstacle general use has been re- moved. Today its cost per pound close that ordinary steel that many applications actually costs less per unit strength than plain steel. Thus meets all the requirements set for the ideal material for lightweight construction—it has great strength, superior endur- ance and stamina, unusually high corrosion resistance. Its cost reasonable. why not build lighter with Why not get rid excess weight that costs you money every time you move it? Find out how little costs apply your equipment. Our records its use thousands lightweight freight cars, high- speed passenger equipment, the new streamlined trolleys, trucks and buses, tractors and trailers, steam shovels, cement mixers and mine skips, mobile equipment all kinds, are available guide you its economical application. > i j a 1 a I Texaco Crater quiets even old, worn gears and Reduces the noise stopping the undue wear. Crater doesn’t channel, squeeze out, throw off. 12—THE IRON AGE, November 1937 — : NERVES well gears the deafening clang and ring open gears and pinions subdued, working conditions output points upward. This one the big reasons gears with Texaco Crater. Texaco Crater cushions gears tough, wear-defying film that clings. reduces the noise. Stops the undue wear, stop- ping metal-to-metal contact. Used wire rope, Texaco Crater coats each individual wire viscous, weather- proof, corrosion-resistant lubricant that penetrates the very center strands. you are now using gears and wire rope lubricants that channel, drip, ball and throw off, over Texaco Crater. Trained lubrication engineers are avail- able for consultation the selection and application Texaco Industrial Lubri- cants. Prompt deliveries assured through 2070 warehouse plants throughout the United States. The Texas Company, 135 East 42nd Street, New York City. FREE YOU... 32-page book- let money-saving information the use and application Crater. Shows bow Texaco Crater merely coat the simple rigs for applying Crater wire rope. throw off bigh speeds around small sheaves the very core the rope, lubricating and preserving it. RATER rite for your free copy. THE IRON AGE, November 1937—13 { th - — a Pe You tell the good feel Bethlehem Steel Pipe when cut threaded—a feel that means, experienced hands, good, sound pipe. Bethle- hem Pipe readily takes the clean, accurate threads that are sign soft steel, free from in- clusions and hard spots. Bethlehem Pipe free from scale, inside and out. And above all, Bethlehem Pipe soundly free it’s good pipe from pin-hole leaks; free from any danger splitting rupturing. Available through your distributor, all standard sizes and weights. Either open- hearth steel Beth-Cu-Loy rust-resisting copper-bearing steel. a 14—TH IRON AGE, Call your Warehouse Steel users large and small find Jones Laughlin Warehouse Service fast economi- complete dependable. You, too, will get steel quickly...in ready-for-use form from your Warehouse. J&L Warehouses are conveniently located. They carry high quality steel products meet your individual requirements for safety Warehouses are fully equipped for bending, forming, welding, cutting and fabricating steel meet your exact needs. Your J&L Warehouse saves you money and prevents delays. When time means money for high quality steel products order from your Jones Laughlin Warehouse. Write today, your business letterhead, for your J&L Warehouse Stock List. JONES LAUGHLIN STEEL CORPORATION PENNSYLVANIA MAKERS HIGH QUALITY IRON AND STEEL PRODUCTS SINCE 1850 THE IRON AGE, November oF "VER NE FOR EVERY NEED furnace gas the one-way fired pit with straight coke oven gas conventional reversing pits. Let engineers tell you how can utilize straight blast furnace gas with all the advantages HAS BEEN TESTED EVERY TYPE MACHINING MIDVALE’S OWN SHOPS Hogging large forgings and micrometer finishing small parts—such are daily examples Midvale production. The same problems prompt delivery, continuous shop production that face you, face us. And you have found, have Midvale, that single factor affects both these items more than the quality tool steel used. Whatever your machining problem, practi- cal certainty that Midvale has had solve it, here, our own shops. Just you can solve yours— with Midvale tool steel. THE MIDVALE COMPANY NICETOWN PHILADELPHIA OFFICES: New York Chicago Pittsburgh Washington Cleveland San Francisco IRON AGE, November 4 oF a | With the precise regulation timing and current provided Westinghouse Controls, you can definitely cut costs all types resistance welding. output, higher quality welds, and lower maintenance costs, can attained simply adding Ignitron Controls your present equip- ment—and specifying “Ignitron Control” new welders being purchased. And cut costs still further, consider Ignitron Timers for resistance welding many products, metals and alloys for which more expensive fabricating methods are now being used. you have problem cutting costs, speeding production, improving quality resistance welding operations, in- vestigate Westinghouse Ignitron Welding Controls. Write for complete information today. 4 j This metal fabricating plant (name request) uses 29West- cut costs and improve quality 3 — YOU USE RESISTANCE WELDING for ALLOYS ALUMINUM BRASS COPPER NICKEL STEEL STAINLESS STEEL combinations these metals? so, will, pay you investigate Ignitron Welding Controls. Write today for booklet 2123. Westing- house Electric Manufacturing Company, East Pittsburgh, Pa. BUILDER BETTER 20—THE IRON AGE, November 1937 4 os A a “It takes years and years grow oak, not raising but the LDING ELECTRODES ALL ANALYSES af . | BEARINGS CO., INC. While watching modern dock machinery handle huge tonnages coal, ore stone, have you ever stopped consider the vast amount technical knowledge required produce such equipment? For over years, Industrial Brownhoist has built locomotive cranes and heavy dock ma- chinery—has passed down the experience gained one generation engineers the next. each modern Industrial Brownhoist may said took over years produce that costs. you have not checked into your handling methods recently, will pay you make use Brownhoist’s experience and so. The savings which can effected nearly every instance, prove decidedly worth while. Each the three Industrial Brownhoist car dumpers shown above will dump 120 tons coal per minute. The bridge crane, the right, has bucket capacity tons ore. INDUSTRIAL BROWNHOIST CORPORATION General Offices: Bay City, Michigan District Offices: NEW YORK PHILADELPHIA CLEVELAND CHICAGO NES, 200 TONS CAPACITY ORE AND COAL HANDLING BRID CAR DUMPERS FOR COAL AND CLAMSHELL BUCKETS LOCOMOTIVE CRA 22—THE IRON AGE, November 1937 ; \ Parts Cost Cut Half Switch Inland Steel Have You Recently Checked Materials Your Plant? It’s preserving constant lookout for small wastes that keeps manu- facturing costs low. Those wastes creep unseen into cost then grow and multiply into substantial losses over year’s time. For example, manufacturer vehicle bodies was using expen- sive non-ferrous metal for difficult, small circular stamping. Inland Deep Drawing Tin Plate proved just satisfactory for the purpose and made big saving material cost. Inland field men and metallurgists are constantly devoting their time making savings the fabrication and uses steel. You can utilize their efforts the cost-checking procedure your plant with- out cost obligation. Just call your nearest Inland office. Offices And Inland Mills are able follow through! The close cooperation be- tween Inland field men and mill men quickly and definitely adjusts today’s most modern steelmaking facilities each indi- vidual requirements. Photo shows Roughing Stand Inland Hot Strip Mill. | L N P The performance your Turret Lathes reflects the Accuracy LANDMATIC The application LANDMATIC Die Heads your Turret Lathes effects immediate improvement their performance. Both the Accuracy and the Quality finish your threads will reflect the precision construc- tion LANDMATIC Die Heads. The simplicity their design, and the materials used the construction LANDMATIC Die Heads assure more accurate results. The Accuracy LANDMATIC Heads and the Economy the LANDIS Patented Tangential Chaser guarantee modern production possibilities for your Turret Lathe threading operations—at reduced operating cost. May send you more information? Write today. LANDIS MACHINE COMPANY, Inc. Waynesboro, Penna. 24—THE IRON AGE, November 1937 q | | her q q | | q ; 7 | FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Rditor Art Editor Metallurgical Bditor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chieago Clevetand Detroit Editorial Correspondents London, England Cincinnoti FRAZAR Boston Hamburg, Germany LOREN IRWIN San Francisco Asa JR. Milwaukee SANDERSON Toronto, Ontario Birmingham Newark, N. J. St. Lowia TURNER Ruffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Chestnut and 56th Philadelphia, Pa. Editorial and Executive Offices 239 West 39th New York, OFFICERS AND DIRECTORS C. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY P. M. FAHRENDORF BAUR, General Advertising Manager DIX, Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00, Can- ada, $8.50 Foreign, $12.00 a year. Single copy, 25 cents. Cable Address, ADVERTISING STAFF Emerson Findley, 621 Union Bidg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Ma. H. K. Hottenstein, 802 Otis Bidg., Chicago H. EK leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St.. New York W. B. Robinson, 428 Park Bidg., Pittsburgh D. C. Warren, P. 0. Box 81, Hartford, Conn THE RON AGE NOVEMBER 1937 Resistance Welding Widened Tube Control Installs New Production Line for Instrument Sockets How and When Use Gear Reducers ........ European Aircraft Production Drill Making Ford's Village Unit Washington News Plant Expansion and Equipment Buying ................ 110 HAT steps you take processing steel? Forg- ing? Machining? Heat treating? combina- tion all three? important that the steel maker know this— for the ideal forging steel not necessarily the ideal machining steel; steel which may excellent for machining may not meet heat-treating requirements. When necessary balance these various requirements, fit your particular process- ing, VisControl gives Bethlehem big advantage. For with this new and more efficient control, Bethlehem 26—THE IRON AGE, November 1937 can fitted your particular processing can aim for the best quality combination qual- ities with assurance hitting close the mark. The VisControl process Bethlehem develop- ment. makes possible the control phase steel making never heretofore under such close regulation —degree oxidation the open-hearth and sub- sequent deoxidation the molten-steel bath. The result exceptional uniformity the steel, one heat compared with another, and remarkable con- trol over each the factors which influence ma- chinability, hardenability, and surface the steel. q | q STEEL 4 : + November 1937 ESTABLISHED 1855 Vol. 140, No. THE Proving That Black White HERE old saying which has been handed down from generation generation and which supposed characterize one who has attained the highest degree skill the art sophistry. such one said: can prove that black Sophistry, you know, the art presenting your argument such complex and involved way that your listeners forget the logic the chain reasoning and accept erroneous conclusion fact. One the classic examples sophistry the proof that cat has ten tails. Perhaps you remember how the argument runs: cat has nine tails, one cat has one more tail than cat; therefore, one cat has ten Millions susceptibles, probably, have swallowed this bit sophistic reasoning whole and firmly believe that there are cats with ten tails each, the fact that they have never seen one and never will. Protagoras, the father sophists, five centuries B.C., through elab- orate but fallacious chain reasoning, proved the satisfaction his followers that there such thing objective truth; other words that black may white. probably took the eminent Protagoras many, many years construct the plausible but erroneous chain reasoning which enabled him prove that black white. the doing it, probably required many thousands words argument and exposition. How far have advanced efficiency since the days Protagoras! The modern sophist can give his predecessors cards and spades and beat him the game. Today have seen that possible convince America that Black white without saying single word! q j welds being made with Ignitron timers. ABOVE IG. 1A—Spot Weld Samples: (1) Tan- talum grid structure large radio transmitting tube showing weld consist- ency; cycles timing. (2) in. thick aluminum sheet; cycles timing; welding 20,000 amp. Section the side- walk structure the Smithfield St. bridge, Pittsburgh. 0.81 in. thick; timing welding current 28,000 amp. (4) 0.064-in. thick brass pieces 0.064-in. thick mild steel strip; timing cycles. (5) 0.064 in. thick steel strips, four welds invisible one side. Edge turned show opposite side one weld. ° ° ° RIGHT IG. 1B—Projection Weld Samples: (1) Pressure tight fitting. Pressed cup welded screw machine part with in. diameter projection weld. (2) Perma- nent magnet. Hardened magnet steel horse- shoe welded two mild pole faces. Each weld in. long, and pole face gap held close tolerance. (3) Metal igni- tion tube parts. Anode lead-in Kovar eye- let welded mild steel header with in. diameter projection weld; vacuum tight. {4) Silver contacts with steel backs welded cadmium plated brass, spring steel, and mild steel. FOR years, may said, resistance weld- ing* has been electric- ity applied the black- smith’s art. Steel only was welded and heat generously supplied practically allow forging well. fact, operators commonly guided their technique redness the parts. Automatic when employed, was measured seconds. The process, therefore, was largely confined the coarser The term “resistence employed this paper applies only resistive type welding maintained high contact pressure between welded parts. Flash welding not included. 28—THE IRON AGE, November 1937 sheet steel structures which toler- ate such undesirable welding after- maths severe electrode mark- ing, warping, blackening and scal- ing. Within the last several years, however, resistance welding has become precision process. Exact fractional-second timing low 1/120 sec. largely responsible. Today, steel welded without warping, burning marking the exposed surface. Plated stocks are welded with lit- tle surface disturbance. machined mechanical parts are welded for accurate fit. Fully esistance ° DAWSON Westinghouse Electric Mfg. Co. East Pittsburgh, Pa. ° ° q important, resistance welding has been extended wide variety the modern alloy metals such brasses and bronzes, and non-ferrous metals sharp fusion point, such aluminum. Some examples the new welding are shown Fig. Coincident with improvement quality has been improvement welding speeds. short, the resis- tance welding machine has been fitted with index magazine feed and placed the modern produc- tion line. high 120 ft. per min, continuous formed channel being fabricated from steel strip 4 aa > 4, | % q 4 4 Bi | | || 4 | 7 é with 3-in. spaced spot, each the equivalent rivet. Before describing the nature these improvements and the man- ner which they apply specific fabrication problems, review will made the various factors resistance welding and the means which have been applied for their control. The Resistance Welding Process Resistance welding may de- scribed the one type electric welding not accompanied flashes, clamping together metal parts and then fusing together their ad- joining surfaces resistive elec- trical heating. electrodes apply the parts both pressure and current. welding sheet semi-flat structures, electrodes small contact area are generally employed concentrate both pres- sure and current the point RIGHT IG. Weld Samples: (1) In- strument pivots 0.018 in. diameter, hardened steel welded end 0.007-in. thick steel ribbon. Cut apart for individual pivots and cemented coil shown. (2) Steel tubing in. pre-machined. (3) Formed tubing 0.50 in. diameter with end notched weld hexagon screw machined drilled after welding. (4) Radio tube shell, mild steel welded mild pressed bottom. Shell before welding shown. Timing cycles; welding cur- rent, 35,000 amp. EXTREME RIGHT IG. 1D—Seam Weld Samples: (1) Olympic bronze 0.05-in. thick test pillow. Pressure tight seam weld, cycles “‘on,” cycles speed ft. per min. Material failed near edge weld 480 Ib. per sq. in. hydraulic pressure. Nipple gas welded. (2) Olympic bronze 0.05-in. thick seam welded note stitch effect. (3) aluminum thick, pressure tight seam weld with one sheet torn away; cycles cycles speed ft. per min. (4) Spaced spot type seam. Similar applications service 120 ft. per min. ing Widened Tube POT, butt, projection and seam welding and the factors influencing quality and cost are this article. section weld timing includes data igni- tion equipment, both for spot and seam welding. sec- ond part, published early issue, the authors outline the advantages re- sulting from the accurate control afforded electron tube timers, and describe number interesting appli- cations ignition tube equipments. weld. Examples are: spot welding using stud-type electrodes and seam welding using wheel-type electrodes. the other hand, when parts are formed inherent- contact each other limited area, electrodes flat faced clamping die form may used. Examples are butt and projection welding. flowing from copper electrode copper electrode through the work pieces, welding current en- counters resistance principally its contact point. Heat gener- ated, therefore, exactly where needed fuse the work together. The amount this welding heat proportional the welding cur- rent, the time its flow and the resistance the junction point which, turn, dependent upon the pressure. Further, the degree spread this heat through the parts during welding also pro- portional the welding time. Therefore, the three major vari- ables involved proper control the process are: (1) Current mag- 7 SPOT WELDER Po int e des (Multiple spots) Multiple Flat electrode (A) (B) nitude; (2) time current flow, and (3) pressure. Proper coordination these variables and precise control each necessary produce welds of: (1) Maximum strength, with, (2) minimum indentation, dis- PROJECTION WELDER BUTT WELDER coloration, metallurgical change warping, and with (3) high de- gree consistency between welds. Too long weld timing, much several seconds has, the past, been the chief departure from best welding practices. now recog- spot welding timer intermediate rating using sealed-off tubes. 30—THE IRON AGE, November 1937 2—Schematic views various types resistance welding machines and timers, together with cross-sections typical welds. (D) nized that the majority welds should made less than sec. and low 1/120 sec. duration. Short weld timing inherently more control with ac- curacy than either current mag- nitude pressure because the mechanical and current interrupt- ing problems involved. Within recent years, however, there have been the market electronic timing control equip- ments which interrupt small enormous current with all but ab- solute accuracy even with weld timing low 1/120 sec. The achievement such accuracy these electronic controls has not only accelerated the improvement non-letronic timing controls but has also brought light lesser in- accuracies the control all fac- tors resistance welding. Once known, such inaccuracies have been readily improved. short, elec- tronic timing has caused wide ex- tension the field usefulness resistance welding. The equipment required ap- plying resistance welding now generally assembled what known the welding machine, which power delivered through some form separate timing and interrupting device. some cases, particularly mechanical timers and contactors are used, these are also built into the weld- ing machine, The Resistance Welding Machine The welding machine applies pressure and current the parts being welded and made any a 4 SEAM WELDER | | ° ° | J the several forms known spot, projection, butt seam welders. The fundamental differ- ence between these ma- chines the form the welding electrodes which consist studs for spot and projection welding, dies for projection and butt weld- ing and wheels for seam welding. These electrodes are generally made from hard copper alloys, and are usually water cooled increase their life. The machine consists rugged framework which houses transformer and supports electrode arms, electrodes, and electrode operating mechanism shown schematically Fig. Since resistance the metal parts being welded low, extremely high current required gener- ate welding heat. The transformer, therefore, steps down the volt- age suitable value, usually volts, with corresponding weld two pieces pipe cross section. The pipe may may not beveled shown. electrodes 5—Seam roller welding bot- tom into cylindrical container. secondary current many thou- sands amperes and equipped with primary winding taps for electrode arms and transformer. More important, however, the inductive reactance the inno- cent appearing circuit loop from transformer arms, electrodes and work. The reactance this look high assume predominant control welding current—the resistance playing little part. Thus, the electrode arms are doubled length, the secondary voltage re- quired force given current through the work circuit will approximately doubled. now evident that the required weld given material depends more upon the dimensions the welding machine throat necessary receive the work than upon the thickness two even several sections material. The power factor welding machine almost invariably poor because the large proportion seam welding timer installation. The insert shows the timing disk with pin clamping disk re- moved. inductive reactance the secon- dary circuit. seldom that ma- chine power factors better than per cent are obtained. Power more common for standard sheet current adjustment large range current adjustment re- quired, auto-transformer added having both coarse and fine steps adjustment. The transformer secondary volt- age usually dictated the total metal welding machines. some impedance the flow welding cases, however, power factors current which consists partially high per cent are obtained resistance material, electrodes, but usually machines with die THE IRON AGE, November : { ] ? | Tubes the desired shape and size are OD. 4) control 7—Two timing methods with typical current and wattage wave forms. timed contactor adjusted for cycles but showing typical timing errors. Weld (A) Using No. total watt-seconds heat input 193 per cent correct cycle timing heat. Weld No. total heat per cent showing serious inconsistency heat input. (B) Using ignitron timer also adjusted for cycles. Welds Nos. and are identical, showing consistency timing and heat input. type electrodes especially designed weld compact although some- times heavy parts. The power fac- tor little affected the resis- tivity the work. There are several methods applying pressure the work but air regulated pressure com- ing more and more into favor since provides reliable and accurate electrode pressure control together with convenient adjustment. Sev- eral other means, either mechan- ical combination air and me- chanical nature, are often em- ployed. Each these has its merits for certain applications. other variables, notably timing, have been subjected precise control, has also been necessary refine the methods controlling pressure. Spot Welding Spot welding performed using stud-type electrodes with small area tips which concentrate both pressure and current for welding metal sheet other semi-flat structures. Such welding ma- chine shown schematically Fig. together with cross-sec- tion typical work. The pressure first applied and when reaches full value, current turned the timer for preset time dura- tion. After the current turned off, the electrodes again open. Modern spot welding machines are often provided with repeat type control with which spot welds are automatically made rapid suc- cession, sometimes the rate Current happens incorrect point voltage wave pressed one both work pieces. When power applied, welds are made wherever the projections contact the mating work piece. Fig. shows one type pro- jection weld. tube parts shown Fig. are joined with vacuum tight projection weld which, this case, com- plete circle. projection welding, the weld area determined size the projection rather than electrode contact area, Rather than make individual spot welds, several projections are often used shown Fig. and all them welded simultaneously. Labor costs are reduced although the instantaneous power demand increased several hundred per cent. Butt Welding Butt welding similar pro- jection welding except that 7-A two more per second. This type control merely repeats, the desired rate, the sequence described the preceding paragraph. such welding, the operator closes the control switch and thereafter acts only move the work after each individual spot weld when the electrodes open. Repeat control often applied the gun-type spot welder which moved from weld point weld point while the bulky sheet metal structure remains sta- tionary. Gun welders are similar ordinary spot welders except that the transformers are separately mounted and its secondary leads are flexible and ft. length. Thus the electrodes and pressure mechanism can han- dled the operator, sometimes using counter-balancing device. Projection Welding Projection welding essentially form spot welding utilizing similar machine except having flat die-type electrodes. Prior welding, one more projections projection raised either part. Die-type electrodes are generally employed. Rods, for instance, are joined end-to-end butt welding. Two lengths pipe may joined, shown Fig. form almost the equivalent seamless continu- ous pipe. The joints are neat appearance, mechanically strong, pressure tight and have metallur- gical properties almost identical with those the parent metal. manufacturing enamel ware, han- formed from thin sheet metal are butt welded pots and pans prior enamelling. Seam Welding Seam welding, sometimes called line, roller stitch welding, con- sists long series spot welds made rapid succession wheel-type machine. Pressure not removed between spots and the wheel electrodes move continuous- ly. The individual welds may spaced some distance for high production speed seam welding 32—THE IRON AGE, November 1937 A | Graphite anode Ly -_ Power Assembly (/ Watts | q q which mechanical strength only desired. More commonly, the in- dividual welds overlap one another form gas and liquid tight seams for vacuum pressure tight ves- sels. Seam welding particu- lar value joining parts having flat cylindrical surface over which wheel can conveniently travel. Fig. illustrates one meth- welding bottoms into con- tainers. Lineal speeds 120 ft. per min. are being obtained with spot spacing in. This requires ac- curate 1/120 sec. timing current 480 interruptions per minute. Seam welds are made for liquid tight service speeds ft. per min. although from ft: per min. more typical for steel. Lineal speeds for aluminum and various alloys are usually less than half that steel the same gage. Although continuous alternating current can sometime used for seam welding steel, now gen- erally recognized that even steel can welded with superior results using current which interrupted high rate speed and with accurately timed regularity. Cur- rent interruption usually essen- tial successfully seam weld aluminum, stainless steel and other alloys. Ignitron timers, such Fig. operating synchronism with the power source have proved emi- nently suitable for seam weld tim- ing since time cycles “on” and cycles “off” and their ratio one Current Contactor close correct point wave speed service. The ignitron timer for seam welding described later section this paper. Weld Timing The timing welding current accomplished one several ways: 1—Manually timed magnetic contac- tor. 2—Mechanically timed magnetic con- tactor. timed magnetic 4—Synchronous motor operated con- tactor. 5—Electron tube timers (not includ- ing contactors timed tubes.) The first three methods timing are relatively inexpensive but their use limited the more readily weldable materials and also spot, projection butt welding. Inherent accuracy limitations often preclude their use the new short- time welding with its exacting re- The synchronous motor operated contactor may also used for seam welding and relatively in- expensive method obtaining higher degree timing accuracy than can obtained with the first three methods mentioned. has certain disadvantages, among which are non-flexible adjustment and the necessity adjusting and main- taining the device close and open its contacts the exact zero point the current wave. This zero point—the power factor—shifts the work, especially steel, fed into the throat the welding ma- chine. Also, proper maintenance separate FIG. 7-8 another must generally repro- ducible high degree pre- cision. Also, the interrupting de- vice must capable enduring the high speed operation neces- sary without undue maintenance. Interruption speeds modern seam welding range from 250 2400 per min. Mechanical devices are entirely unsuited such high always conducting correct point voltage wave often difficult practice, owing mechanical wear. Ignitron Spot Welding Timer The ignitron spot welding timer, Fig. has proved eminently suited the requirements precision spot, projection butt welding (7). This timer inherently oper- ates terms half-cycles or, 1/120 sec. increments welding current. designed and cali- brated apply power the ma- chine for timed interval which composed adjustable exact number half-cycles within cycles. High operating speeds are attained with thoroughly depend- able reproducibility. desired, timing may adjusted cycle increments, although standard timers are calibrated one cycle steps. Essentially, the power tubes serve single-pole, fast-acting switch operating noiselessly and without the usual are burning. The primary current the welding machine carried and interrupted entirely ignitron power tubes (4) (5) (6). mechanical electromagnetic device affects the timing. common with electron tubes, ignitrons are not subject mechanical wear are burning. Fragile filaments are not employed the ignitron which consists vacuum-tight inclosure metal glass the bottom which pool mercury that serves one electrode. dis- tance above the mercury there another insulated electrode, made graphite. For the third elec- trode, and place grid, igniter “spark plug” em- ployed. This igniter in- sulated from the two main elec- trodes although partially im- mersed the mercury pool. The ignitron will not conduct current until small ignitron current passed through the igniter the mercury pool. The tube then in- stantly “ares over” and becomes (CONTINUED PAGE 81) always conducting (As FIG. 7-C THE IRON AGE, November q Watts AE Installs New Production Line For MILLER DETACHABLE watt- hour meters that can plugged into cir- cuit with somewhat the same ease electric iron other household appliance have been production the Newark, J., plant the Westinghouse Electric Mfg. Co. for the past years. They are made largely for public utilities. Mounted the outside residences and other buildings, they permit the reading meters without disturbing the subscribers. Recently* the same principle has been applied other types in- struments, types that find wide ap- plication connection with ma- chine tools and other motorized machine equipment. function these plug-in instruments are iden- tical with the previous panel-type, but are mountable directly the wiring conduit and provide plain- visible and unusually means determining any desired load condition. Like the panel-type instruments, they may used prevent loss and waste due improper ma- chine operation. the visual in- dication power input the opera- tor can tell glance when the machine overloaded, either be- cause dull tools from troubles page 59. 34—THE IRON AGE, November 1937 the machine, the motor, control wiring. Thus not only undue power consumption prevented, but slowing down production due dull tools, complete interrup- tion production due breakage tools machine parts can avoided. Electrical instruments can also used show the speed which the various machine units are operating, relative each other, and even the position various machine units the op- erating cycle. All types the new detachable instruments use standard watt- hour meter parts, manufactured high-output, low-cost basis. The development detachable watt- hour meters and instruments has required expansion manufac- turing facilities, notably for the production the socket mount- ing unit. Some the features this new production layout are out- lined this article. Component members these plug-in instruments are shown Fig. There are two main units, namely, (1) the instrument mech- anism which mounted plate and has electrical-connection blades the back, and (2) the socket mounting device which has elec- trical connection jaws receive the instrument connection blades. The socket designed for mount- ing directly the wiring conduit the machine, elsewhere. plugging the instru- ment unit into the socket and seal- ing the two together with the seal- ing ring shown, complete instru- ment formed. The combination OCKET for rigid conduit mounting with self-supporting and requires further mounting details. The instrument may am- voltmeter, watt meter, power factor meter various specialty instruments now proc- ess development, such total- hour meters, position indicators, speed indicators. Any these can quickly removed and replaced the “troughs” (all-metal boxes) hav- ing several sockets can used when more than one instrument read the same time. When Standard wiring conduit and the instrument unit ugged ring shown 4 i . —— — F rigid q | elec into 7 the rigid connection jaws and instrument unit. detailed analysis motor de- sired, the instrument can re- placed plug-in testing jacks with cable connections permit use complete portable analyzer (see Fig. 4). Furthermore, con- tinuity devices are available that these plug-in sockets, located either the machine elsewhere conduit line for future use, may sealed off until wanted. Two types the plug-in socket receptacle are made. One the form die-cast ring for mounting integrally the frame electrical instruments. The socket mounts the into it. The two are then sealed together the the extreme right. machine the factory, and the other, shown Fig. die east socket for installation the pipe conduit that carries the wir- ing the motor. the latter that mainly dealt with here. Socket Production Continuous Production the sockets con- tinuous, from the feeder sections sub-assembly and main assem- bly benches. Completed units travel very short distance roller conveyor packers, who box them for shipment stock. The socket member alumi- num die casting about in. diameter and has bosses the in- terior, shown, for reinforcement the conduit assembly. The first operation, done feeder section immediately adjoining the main and sub-assembly benches, the drilling and tapping eight more holes, two more for con- nection the conduit, four ter- minal block mounting holes, and two holes for wall mounting. This done the Kingsbury drilling and tapping machine, Fig. equip- ped with four tapping units ar- ranged tap all holes simultane- ously, each unit going through its cycle and then stopping. Each unit contains air cylinder for trip- ping the feed and all four cyl- inders are connected one control valve. These tapped holes for the in. diameter, and sockets with either two three-way tapped outlets can furnished. This Kingsbury machine equipped with one the new de- tachable instruments, this case ammeter, means which the condition the taps and other tools closely watched order avoid poor workmanship and the slowing this operation. When tapped, the sockets slide gravity conveyor that takes them through washing ma- chine and drying oven. They then spray booth for lacquering, priming and final coat being applied. The lacquered sockets then pass another drying oven, vertical ferris-wheel type, and then the first series assembly operations. Terminal Blade Jaws Made High Rate previously mentioned, the socket member contains within set heavy-duty connection jaws that receive the mating elec- trical connection blades the in- strument unit. These, together with the terminals for connecting the external load are carried Moldarta molded com- position terminal block. Terminal blade jaws are made No. multi-slide machines (see Fig. 3). Phosphor-bronze strip stock 0.047 in. thick and about in. wide pulled from stock reel through straightener, the stock then passing successively through series dies. first pierced, formed and cut-off; then picked another tool and further formed three successive operations. Finally, operated stripper ejects the piece into tote THE IRON AGE, November Detachable Instrument Sockets box through the base the ma- chine. The same battery high pro- duction machines employed for making the sealing ring bracket, shown the lower right Fig. These are made from brass stock 1/16 in. thick and in. wide. Successive operations are: Piercing two holes and three slots, countersinking the blanking and returning the blank the strip, cut off, and forming shape. The machines doing these com- plicated power press jobs are en- tirely automatic. effect, they comprise number shafts sur- rounding the main machine bed; from these shafts horizontal and vertical slides are operated means cams eccentrics, the work requires. The shafts are gear driven, and changes production speeds suit different set-ups are accomplished merely changing the gears. Terminals Made Screw Machine outstanding machining op- eration the production the terminals for connecting the exter- nal load circuit. These are made from in. diameter brass rods Davenport five-spindle automatic screw machine especiai- 36—THE IRON AGE, November 1937 2—High pro- duction drilling and tapping the socket member, aluminum die cast- ing. One the new detachable instru- ments regularly used this machine for determining when the taps and drills need resharpening. 3—Contact terminals for the plug-in sockets are produced high rate multi-slide automatic machines. From the reel, the phosphor-bronze strip stock goes through straightener and then through series piercing and forming dies. tooled for the job. Operations are: Drilling and tapping; cross drilling the end; turning down size; threading; and broaching the shoulder prevent turning the assembly. These pieces have held within few thou- sandths inch, particularly the threaded portion. Subsequent processing includes cleaning potash solution for removing oil, bright dipping remove scale, and tin plating, the latter done for the most part barrels. Other feeder sections manufac- ture the sealing ring and the in- strument mechanism backing plate, both which, with the parts mentioned above, end the as- sembly and packing departments. The sealing rings are made from BELOW 5—Assembling the terminal blocks. All assembly operations have been time and motion studied and equipment provided assure maximum economy time and effort. a > ABOVE presses the Newark have also been equipped with plug-in type ammeters permit convenient check how stock running with respect thickness and hardness and when the tools need resharpening. this case the ammeter has been replaced test jack with cable connection portable industrial analyzer for making complete analysis motor operation. tinned copper strips. punch press with coil-feed blanks, and countersinks holes the strip stock, which subsequently cut and formed into rings, the latter conventional horizontal mill- ing machine equipped with in- genious special fixture and special rolling tool. The milling ma- chine used principally con- venient means variable-speed drive. The instrument backing plate, which forms the base foundation for mounting the instrument ele- ments, blanked and formed Bliss No. 306 straight-sided press equipped with suitable combination blanking and forming dies. made strip steel stock, 0.62 in. THE IRON AGE, November 4 thick, about in. wide and ft. long. Several the presses this department are equipped with one the new detachable instruments. the case the machine shown load the machine drawing, any inconsistency operation being immediately known. this way the operator can determine when tools need replacing see how his