The Iron Age 1938-01-20: Vol 141 Iss 3

DEPARTURE Ball Bearing MEET THE His name “Otto” (Automatic) Pyrometer. isn’t human appearance—but better than any human being when comes keeping treating furnace the proper temperature for correct grain structure and hardness material well for relieving heading forging stresses Upson Quality bolts, nuts, rivets and other headed and threaded products. Each heat-treating furnace the bolt and nut plants Republic has its own reliable also the Republic metallurgists who check the “Otto’s” reading the lines they make record charts. Automatic pyrometers are but one the many reasons why you always can depend Upson Quality headed and threaded products—one the not little details that make perfection. REPUBLIC STEEL BOLT AND NUT DIVISION Bolts and nuts all standard and special shapes, threaded products for every use. Your specialties are our specialty. GENERAL OFFICES CLEVELAND, OHIO 2—THE IRON AGE, January 20, 1938 AGE, published every Thursday the CHILTON CO. (INC.). Publication Office, Chestnut 56th Sts., Philadelphia, Pa. Editorial and Executive Offices, 239 39th New York, Entered second class matter November 1932, the Post Office Philadelphia under Act March 1879, $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 141, No. f ‘ | j j | — a = OY > > i L A Yj ditorial under FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnaté Boston Hemburg, Germany Milwaukee San Francisco SANDERSON Asa JR. Toronto, Ontario Birmingham Newark, N. J. St. Louis TURNER Buffalo Owned and Published by CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Executive Offices Philadelphia, Pa. 239 West 39th St., New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANB CHARLES 8S. BAUR G. CARROLL BUZBY P. M. 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. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ‘‘Ironage, ADVERTISING STAFF Emerson Findley, 621 Union Blidg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. . K. Hottenstein, 802 Otis Bldg., Chicago H. E. 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 Bldg., Pittsburgh D. C. Warren, P. O. Box 81, Hartford, Conn. JANUARY 20, 1938 Two Thousand Mile Dog with One-Inch Tail Structural Steels During Gas Cutting Welding Marches Highlights the Year Metal Finishing Presses and Sheet Metal Machinery Trend Toward Lighter Weight Portable Electric Tools Testing and Inspection Statistics Metal-Working Activity Washington News NEWS CONTENTS ..... Plant Expansion and Equipment Buying Just Between Two Copyright 1938 Chilton Company 116 New for Steel Users The increased production speeds and improved manufacturing standards the last few years have emphasized the need for greater uniformity and higher quality steels. Ryerson began work this problem several years ago. tightening specifications and making inspections more rigid, gradually built stocks these better steels. Today are position definitely and un- equivocally certify the known high quality and uni- formity all steel stock. addition, special plan was developed for the alloy steels degree control never before attempted Principal products stock for Imme- diate Shipment include—Bars, Struc- turals, Shafting, Plates, Alloy Steel, Tool Steel, Spring Steel, Iron and Steel Sheets, Stainless, Babbitt, Strip Steel, Welding Rod, Tubing, etc. any steel service company. Whole heats alloy that measure special Ryerson standards selected. They are accurately identified and tested. Special Data Sheets showing chemical and properties, actual heat treatment response, are pared. This data sent with every shipment alloy The heat treater thus knows exactly what every and how secure the best possible results. Let send you copy the new Ryerson Certified Steel Book Which explains detail how this nev plan will save time and money. Address Ryerson plant. Joseph Ryerson Son, Inc. Plants at: Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. ... THE IRON AGE ... JANUARY 20, 1938 ESTABLISHED 1855 Vol. 141, No. The Two Thousand Mile Dog with the One-Inch Tail radio listener who judged audience response, the most effective part the President's Jackson Day dinner speech had with the 96-inch dog who wagged four-inch tail. How apt the comparison was, denoting the comparative size and power the utility holding companies compared with the electric power industry whole, are not prepared say. But the seeming incongruity huge dog eight feet length, being wagged diminutive four-inch tail, caused the $100 per plate audience de- serving Democrats considerable amusement. also tickled the President, who inter- rupted his address chuckle his joke. not our purpose within our abilities say how long tail should order properly and justifiably wag him. matter fact, dog lovers know who have observed canines all breeds and cross-breeds, tails always wag dogs, even they the abbreviated stumps Boston bulls. Perhaps for the same reason that little rudders can and steer big boats. course, what the President was attempting get across his audience through this amusing metaphor was the danger situation which few people could dictate many people situations concerning large investment funds. Admitting that there are times and instances where even little tail may compel big dog travel directions diverging from his interest, believe that the anal- ysical ogy could applied with even more force outside the field finance. Take Government concentration power, for instance. Our national political econ- steel. omy has been based the belief that safer wagged the tails medium size, the State Governments plus the three coordinate branches the National Government, than one short one. late years, the tendency has been, all know, the direction minimizing the wagging power these tails and concentrating that power just one. arithmetical comparison, the scale one inch per American citizen, that would mean two thousand mile dog being wagged one-inch tail. cago, good analogy one that has number applications. The President, his clever metaphor the long dog and his short tail, has given something think about. H | | | | : | ‘3 | Structural ESULTS microscopic ex- amination and drift and tension tests the heat affect- zones plain flame-cut and flame-softened steels are outlined this part Mr. interesting paper, continued from THE IRON AGE Dec. 30, 1937, page 22. Data are also given comparative costs the different types flame softening, and number applications the process, involving both air and quench hardening structural steels, are listed. ACROSCOPIC scopic tests the heat-affect- zones plain and flame- softened cuts, the latter using post heat, were made concurrently the Union Carbide and Carbon Research Laboratories, Inc., nickel, silicon and manganese structural steels ascertain the depth these zones be- low the surface the cut and the character their structural constitu- ents. The chemical composition the steels investigated, determined the laboratory, was follows: Silicon The depth the zones heated temperatures which were high enough alter the internal structures the steel and thus change their physical properties were found approximate 0.04 0.08 in. in. thick steel, the narrow depth applying structural silicon steel, the intermediate depth structural manganese steel and the maximum depth structural nickel steel. These depths are not material- altered the heavier gages. 22—THE IRON AGE, January 20, 1938 The hardness these affected zones graduates the normal hardness the unaffected parent metal and there- fore the depth injurious hardening was somewhat less than that reported above. there are irregularities the cut surface due improper opera- tion the cutting apparatus, the depth injury must measured from the roots such irregularities. Plain flame cutting these grades causes carburization the surface Nickel Silicon Manganese Structural Structural Steel Steel Steel 0.25 0.36 0.27 0.64 0.94 1.40 the cut depth 0.002 0.003 in. and the cooling that follows cutting rapid enough produce hardening 0.07 in. and affect the structure transition zone approximately 0.015 in. wide which the hardness and the structure gradually vary from the very hard conditions wherein the structural constituent martensite, the original structure consisting pearlite and ferrite produced the normal cooling from rolling tempera- tures. The size the structural constitu- ents the hardened zones was seen much smaller than the parent metal. other words, flame cutting operated refine the grain. Desirable Hardness and Ductility Obtained With each steel, the flame softening operation tempers the martensite and eliminates the structure representing the brittle condition. the flame softening treatment carried be- low the critical point the steel, neither the microstructure the phy- sical properties the underlying steel having normal ferrite structure are changed, but the re-heat- ing does change the martensite struc- ture leave tough and ductile, fine grain steel along the cut edge. was therefore the laboratory’s conclusion that the steel the heat- affected zone which was flame soft- ened post heating, given de- sirable combination hardness and ductility, and the martensitic structure produced the usual flame cutting procedures tempered practically ideal condition. Photomicrographs the three grades under discussion, nickel, silicon and manganese structural steels, which bear out the tions, are reproduced Figs. 11, and 13. The magnification 100 diameters was used for these three figures. Further examinations the affected zones the manganese and nickel grades were made higher magnifications. Figs. 14a, 14b and illustrate the significance post heat treatments compared with preheat treatment flame softening grade steel critically responsive air hardening, emphasizing the need for proper ap- plication the supplementary heat treatirig operations. The material { i 7 q | i i ° ° ° During Gas Cutting— Development Engineer, The Linde Air Products Co., New York this case structural nickel steel was the recommendation demonstrations the company’s Am- 0.33 per cent carbon, 3.21 per cent Goodrich, chief engineer, American bridge plant, that flame softened cut nickel and 0.26 per cent copper. Bridge Co. during the course shop edges representative group high tensile structural steels sub- TABLE AVERAGE COMPOSITION HIGH TENSILE STEELS SUBJECTED DRIFT TESTS Structural Steel 0.35 1.43 0.196 0.028 0.027 steel require this test. substance, O.H. Structural Silicon Steel 0.38 0.86 0.312 0.021 0.034 the test requires that punched Nickel Steel 0.39 0.66 0.124 037 0.020 3.3 drilled holes spaced approximately two Each plate was finished in. in. having the following edge preparations: Edge No. Sheared. diameters from planed edge shall Edge No. Sheared in. full size and planed size. stand drifting until the diameter Edge No. Plain flame cut. enlarged per cent without crackin Edge No. Cut and flame softened simultaneously Type treatment. IG. Structure the cut edge unsoftened nickel steel specimen (x-100). The narrow white band along the cut edge the left-hand side the print may oxide although appearing austenite this magnification. Its thickness the order few thousandths inch and relatively soft. The dark material the interior edge this band martensite that has begun separate from the white constituent while the dark material immediately the right the white band martensite which the print extends for depth in.; therefore the actual depth this material 0.06 in. Then comes transition zone which includes more and more the white ferrite, and finally the extreme right the print shown the unaffected steel whose structure consists ferrite and the dark pearlite. narrow white band proved quite stable heating. However, the martensite has been cular constituent and clear-cut Widmanstatten- Practically eliminated. The transition zone be- tween the tempered martensite and the original THE IRON AGE, January 20, 1938—23 i 2 ‘i | ° : a | 3 : a rs . RIGHT IG. 12-b (x-100). The same shown Fig. 12-a except that here the post heating treatment was used. The light colored zone the treated surface remains but the surrounding metal has been tempered the treatment. The dark zone adjoining the light colored surface layer consists tempered mar- tensite and some troostite. The next the very fine grained sorbitic-ferritic structure which gradually increasing amounts ferrite may observed the unaffected metal ap- proached. ° ° RIGHT IG. 13-b. Structure post heated man- ganese steel specimen (100-x). The surface zone contains much less the white con- stituent and the underlying dark material has lost the acicular appearance that representa- tive martensite. has been tempered the post heating treatment. The transition zone the treated specimen wider, and changes oc- cur more gradually than the specimen that was cut without treatment. 24—THE IRON AGE, January 20, 1938 LEFT IG. 12-a (x-100). silicon steel specimen, cut without the post heating treatment. The irregular light colored area the left ap- pears cementite. surrounded the dark constituent called troostite. Below this irregular surface layer the structure consists mostly martensite, but some troostite pres- ent. the transition zone the white ferrite gradually becomes more sharply defined until the unaffected grains the original structure are reached. The dark material the transi- tion zone fine grained pearlite that was not heated high enough temperature enable transition into harder constituent. ° ° ° LEFT IG. 13-a (x-100). Structure manganese structural steel specimen taken from edge that was cut without the ing treatment. The characteristic outer zone light colored metal has matrix dark Then the underlying dark material martensite with some troostite and small amount free white ferrite. The transition zone fairly narrow, and other speci- mens, the free ferrite increases amount the unaffected structure neared. | 14-a (x-1500). Structure the edge specimen structural nickel steel light-colored edge zone which appeared austenite at 100 diameters (Fig. ll-a) is found this magnification consist two layers; the inside, slightly darker portion, probably represents the first stages the the austenite. This slightly darker zone contains needles martensite extending throughout its limits. The next zone dark constituents, shown the photomicrograph, uniformly martensitic having decided acicular structure. This structure representative steel that hard and brittle. test was carried out three structural steel having the average composition shown Table page 23 . were drilled the quarter points along each side and in. back from means drift pins having diameters progressively increasing in. which were forced through the drilled holes with steam hammer. The center hole and quarter point hole each type edge preparation re- ceived this test. The amount enlargement the drifted holes and the edge deformation are shown and indicated Fig. 15. The planed edges marked No. and the flame softened edges marked No. withstood drifting 9/16 in., approximately 100 per cent enlarge- ment without cracking, which point the test was stopped. The sheared edges, marked cracked visibly during the 5/16 in. mately per cent, while the plain gas cut edges, marked No. cracked during the in. and 3/16 in. drifts, representing enlargements aver- aging approximately per cent. The test demonstrated beyond ques- tion the ability the flame softened edges withstand tests this char- acter. Tension Tests was Mr. Goodrich’s further sug- gestion that large size tension bar tests made the several edge prep- arations provide more practical example for comparative study their effect upon the overall physical 14-b (x-1500). area the border- structure specimen nickel steel which has been simultaneously preheated and cut. The upper half the photograph shows dark martensitic needles geometric- ally spaced background light-colored austenite. There are indications that the austenite has probably broken down into what known white martensite, which could developed deeper etching. The very dark areas the lower half the figure are troostite patches and the lighter areas are sorbite; the white constituent ferrite. This structure also representa- tive steel that hard and brittle. properties the steel, and according- series bars ranging width from in. their reduced sec- tion in. long were prepared three high tensile structural steel. Each series embraced machined, flame-cut edges. The diagrams and detailed informa- tion the bars reproduced Fig. 16, and the mill test report the phy- submitted properties Homestead Plant Steel Co. where these tests were made The physical properties the bars having flame-softened edges are seen good agreement with those having planed edges, contrast the flame-cut bars which failed re- duced The ductility the flame-softened edges comparison with machined and plain flame-cut edges illustrated Fig. for 0.29 per cent carbon nickel steel. loads. The reduction area the flame- softened bar the right the same order that the planed bar the left, while the plain flame-cut har seen have abrupt fracture with negligible reduction area. Cost Flame Softening The cost flame softening for matter increased gas consumption inasmuch the operation carried out simultaneously with cutting and the usual cutting speeds, and there- +e IG. 14-c (x-1500). Structure nickel steel specimen that cut and post heated. The outer wiite layer appears austenite and the lower edge this white material few tempered martensite needles may seen. The white layer did not extend throughout the specimen that was examined. Near the top the plate where the post heating temperature was highest, the structure the cut edge consisted minute spher- oidized particles cementite ferrite matrix. The main dark area the photo- micrograph consists structure which the acicular martensite originally present has been completely spheroidized. This structure representative steel that good respect both toughness and ductility. THE IRON AGE, January 20, 1938—25 ap- the fore, appreciable amount extra labor involved. For the type III treatment, which non-simultaneous with cutting, the costs involve both gas labor. However, with this type treatment the operation usually conducted faster rate speed and therefore the cost this method may only slightly greater than that softened the types treatments for the same unit surface area softened. the neutral flame emploved flame softening operations, the flame heads consume equal quantities oxygen and acetylene for the burn- ing ratio for the neutral flame at- mospheric air for the two gases the order 1:1. For estimating purposes the volume oxygen and acetylene for softening in. in. thick steel the sim- ultaneous type treatment may figured approximately cu. ft. each gas per linear foot cut for each side the kerf softened. For type treatment the consump- tion somewhat lower. For type III treatment, equivalent surface areas can softened with ap- proximately one-third one-half less gas. The gas consumption per unit time dependent upon the size the tips the multi-flame heads and the specific flame characteristics, func- tion gas pressure. The length the inner cone the neutral flame serves yardstick for predetermin- ing heat quantity necessary for any particular operation, and readily measured suitable metal 26—THE IRON AGE, January 20, 1938 SPECIMEN NUMBER KC-1 KP-1 Mill Test NM-1 NM-2 NC-2 NP-2 NP-3 Mill Test SM-1 SC-2 Mill Test FM-1 FM-2 FC-1 FC-2 FP-1 FP-3 Mill Test MM-2 MC-1 MC-2 MP-1 MP-2 MP-3 Mill Test THICKNESS NOMINAL AREA LOAD YIELD POINT 163,880 155,600 164,600 209,100 206,000 226,300 208,600 199,300 197,200 200,300 134,800 123,100 127,800 128,300 121,400 148,600 143,900 149,300 145,300 163,300 178,800 161,300 160,200 162,300 160,600 172,400 171,900 186,100 LOAD ULTIMATE STRENGTH 243,000 202,800 233,600 305,900 306,620 275,300 267,700 296,600 295,900 293,000 250,300 245,700 208,700 226,000 206,800 281,900 281,100 238,300 217,400 282,400 290,300 283,200 285,200 208,600 217,100 278,140 278,200 282,900 Tensile test results (The legend for the the bottom Fig. YIELD POINT 69,580 67,770 72,140 64,370 67,940 67,000 73,280 68,560 64,940 64,780 68,100 64,150 44,020 43,220 41,620 42,130 47,140 49,800 47,790 46,380 48,210 48,040 52,720 57,200 50,340 52,640 52,280 52,710 52,580 57,600 57,130 60,090 68,040 16) ULTIMATE STRENGTH 103,000 88,330 102,400 104,150 99,380 99,710 89,150 87,980 96,620 97,200 99,600 99,420 81,750 79,780 67,960 74,220 80,300 85,525 90,650 90,600 73,800 71,850 91,180 92,830 92,990 92,430 93,080 67,750 71,090 92,940 92,460 91,350 97,700 ELONGATION LENGTH type steel and treatment shown Fic. 15. Drift tests manganese, silicon and nickel steels. Vv 17.6 16.7 3.480 0.875 3.045 1.12] 6.22 23.5 3.400 0.890 3.026 0.44] 2.44 21.0 18. scale. inner cone length ap- proximately 5/16 in. has been found give good results for most applica- tions. Range Application Some the obvious applications for flame softening are here listed, re- ferring quench and air hardening steels Suspension bridge towers: Shap- ing gusset plates, web plates includ- ing manholes, hand-holes and lighten- ing holes web plates. Bridges: Shaping web plates for arch bridges, gusset plates, some cover plates and end cuts for Uni- versal mill plates, manhole cutting truss bridges and web shaping, and 17. Tensile test bars. Note the ductility the flame softened bars (outer) compared with the plain gas-cut edge (center). miscellaneous plates for cambered girder bridges. DETAIL MACHINED, TENSILE TEST PLANED FROM RECTANGULAR BLANKS WIDE Specimens prepared from this sketch: KMI SMI SM2 MMi NM2 MM2 DETAIL PLAIN GAS HEAT TREATED GAS CUT,P, TENSILE TEST SPECIMENS Specimens prepared from this sketch: LEGEND -Nickel 0.33%C. Material preparation Machined Plain gas cut Heat treated gas cut NC2 SC2 FC2 MC2 NPI NP2 MP2 M-Machined specimen gas cut specimen Heat treated gas cut specimen Specimen identification TABULATION NUMBER SPECIMENS EACH KIND. Total number specimens 16. Tension bar diagrams. Buildings: High plates for new and alteration work, narrow high tensile girders. Railroad Vehicles: Low-alloy high- strength steel, plates for slides and bottoms, center sills and built-up and pressed bolsters and side frames, hand and service holes center sills and bolsters, correction cuts. Industrial Straight- line and shape cutting all grades high strength structural steel, in- cluding architectural openings and hand and service holes for finish cut- ting allow free machining. Steel Warehouses: Finish cutting, straight and shape all hard high strength steels, and for annealing sur- faces hardened friction saws they can readily machined, for cut edges high carbon pipe they can machined threaded. Foundries: Softening gas-cut sur- faces for all clean-up cuts casting alloy steels that respond short time heat treatment. Steel Mills: Cut surfaces carbon steels 0.40 per cent and higher, and all alloy grades, prevent crack- ing upon cooling, permit ma- chining for finish cutting cus- tomer’s specifications. Grateful acknowledgment made the American Bridge Co. for furn- ishing the greater part the high tensile structural steels used during the laboratory and field experimental work, and particularly the latter company for furnishing assistance and counsel for shop tests the Ambridge and Gary plants, and for arranging for the tension bar tests the Homestead plant Carnegie- Illinois Steel Co.; and Union Car- bide and Carbon Research Labora- tories, Inc., for concurrent assistance throughout the period experimenta- tion and testing. THE IRON AGE, January 20, j ding arches On! ° ° ° SPRARAGEN Technical Secretary, American Welding Society ° oxy-acet- ylene welding, use indirect resistance welding, production from mod- ern resistance welders, and out- standing applications building and structural steel fab- rication are dealt with this sec- continued from The Age Jan. page 445. Applications other fields are outlined concluding section, appear early issue. company has developed new high ductile gas welding rod designed for increased ductility and improved qual- ity both single and multi-layer welds. Free bend ductility multi- welds, with these from per cent low and medium carbon steels. Ultimate ten- sile strengths are excess 60,000 and Charpy impact values range Another development steel welding rods for air hard- ening steels and low alloy rods for structural steels. the non-ferrous field, new rods and flux for the weld- ing silicon copper have been de- 28—THE IRON AGE, January 20, 1938 ° Several wear-resistant alloys have been perfected for building rail ends and for hard facing valve seats. “wrinkle” bending has been developed for making sharp bends welded pipe lines. the point bend, the welding flame used heat several narrow bands right angles the pipe length and extending about half- ULTIPLE flame cutting permits simultaneous shaping pattern two more identical parts. (Photo cour- tesy Linde Air Prod- ucts Co.) way around the pipe. The pipe thea bent means tractor, causing these heated sections wrinkle. Relatively New Welding Process While developed 1937, there one process which received wide application during the past year. The exact name has not yet been deter- mined. The developers believe most ac | he m | to re | | m m 4 ol ol | as | ag ne th a | | | vil resistance method. Others that the nature the product could more accurately described “submerged Time and experi- mentation will bring forth the correct nomenclature, but any event, indus- try has acquired remarkable new tool using extraordinarily high cur- rents for repetitive welding heavy plates. large diameter may used and small welds may made plates in. and in. thick under the protective influence molten flux with speed and quality weld almost unbelievable. How many recall the upper limits current and the diameter elec- trodes that were specified two decades ago? How these compare with the new process mentioned above which thousands amperes passing from the electrode the plate through pow- dered flux which poor conductor when cold and conductor when hot, enables the welding 3-in. thick plates single pass? Resistance Welding Speeds Production are some examples auto- matic welding the resistance field: Rims that one time welded using two men welder the work clamping, flashing and push were controlled manually. day’s work its peak was some 1300 rims for nine hours for two men. Three thousand five hundred rims using fully automatic welder, air operated device and hydraulic push ABOVE pressure cylinder yoke was flame-cut the Lukens Steel Co. from thick steel plate. in. long overall, in. wide its widest point, and weighs 6735 Featured are the octagonal shaped ends. RIGHT ONSIDERABLE flame cutting and welding were employed the construction this heavy base for tilting table used sheet mills. (Photo courtesy Champion Rivet Co.) HIS 350-ton C-type frame, weld- fabricated Lukenweld, Inc., ft. in. high and weighs 28,000 The lower platen measures in. Deflection along the center- the ram under 350-ton load 0.15 in. per min.; now ft. per min. Spot welders were made oper- putting automatic control welders the speed has been increased 200 more spots minute. complete steel floor the THE IRON AGE, January 20, 1938—29 1 q ABOVE INE these viaduct expansion joints were weld fabricated. They were cut from 2-in. plate, in. wide, means Oxygraph machine. The side each joint made five 10-ft. pieces, each which re- quired ft. cutting. Regarded unusual job machine gas ting both because the necessity holding ex- act form and dimension and the cost involved large pieces. Photo courtesy Air Reduction Sales Co.) Chrysler “Royal” motor car and give greater strength and rigidity, some reinforcing pieces are placed massive new hydromatic welding ma- chine and the operator throws the switch and 164 points are welded sec. Extreme Flexibility One the developments which re- ceived considerable attention this year the so-called “push” “poke” re- sistance welder. This development, which lay dormant for number has been revived with excep- tionally good results. This has been made possible modern resistance welding electrodes, water cooled, and timing devices which accurately con- trol the current. some forms IRON AGE, January 20, 1938 ° RIGHT multiple spot weld- for high produc- tion welding metal pickup boxes. The boxes are welded several sections, the fixture moving step step into the welding machine, which equipped with weld- ing guns and two transformers. BELOW NUSUAL type welder built the Federal Machine Welder Co., for welding automobile and truck mufflers. Pressure consum- mate the weld ob- tained from motor- driven oil pump, which also acts timing device. Two mufflers are welded one time. automobile body construction, welds have made places difficult get at. These new resistance welders enable one part the electrical cir- cuit grounded ft. away from where the welding operation being straight electrode tip can inserted and the operator able exert ficient pressure, weld excellent quality can made fraction second. Spring pressure controls many cases remove what left the “human element.” Welded Ships would have done some the old- timers who used members the Emergency Fleet Welding Committee good have witnessed the launching the world’s largest welded ship Chester, Pa., the Sun Shipyards, last November. These fellows during the war days used dream all- welded 5000-ton vessel. The “J. Van Dyke,” which joins the Atlantic Refining Co.’s fleet, has deadweight capacity 18,500 tons. The vessel, 541 ft. in. long with beam molded depth ft. and draft ft. in., has cargo capacity 6,552,000 gal. and will make 13.25 knots hour. This will enable run between Philadelphia and Texas Gulf ports the unusually fast time six days, and the pumping equip- ment will make possible the discharge cargo the rate 630,000 gal. hour, about three times the usual dis- charge rate. Structural difficult single out any structure being outstanding, but welds ult elders from being ellent ols the old- the nittee ching uring all- eight essel, ft., draft 13.25 time dis- any but new State Armory Schenectady, all welded building, unique claims upon the attention engineers and construction has the largest welded plate girder and the largest welded arches any the United States and continuous welded floor framing de- signed increase the strength and the floor. The plate girder, ft. long, was fabricated the are welding process. This year, some engineer- ing editors were invited witness the world’s largest telescope mounting— outstanding welded structure. Re- markable, not only because its size, but also because the accuracy with which must fabricated and ma- chined. The complete telescope mounting will weigh more than 1,000,000 Ib. Welded construction was adopted make possible large savings weight, without loss rigidity. The mount- ing comprises two major units: the tube and the yoke which the tube swings. The tube, which ft. long and ft. diameter, supports the 200-in. reflecting mirror and con- tains compartments house the prime focus and auxiliary mirrors and the One end the yoke consists giant bearing having the shape horseshoe. This bearing ft. diameter and ft. in. thick. The swivel ft. long ft. deep and wide, which turns ball and socket bearing that floated oil. The ends the yokes are joined to- gether two hollow tubes ft. long and 10% ft. diameter. All sections the weld-fabricated mounting are carefully strain annealed special furnaces. new type welded design which utilizes columns has been developed one leading fabricator. the elimination the cross mem- bers and trusses, the building attains per cent availability clear area from floor roof. Several large buildings erected during the year used this form construction. The “tree-form” sections were de- signed for welded construction. stated that the cost using them any other type fabrication would prohibitive. The sections are en- tirely plate-fabricated arc welding. The components, cut and rolled proper size and shape, are placed jigs, clamped, tack welded, then finish welded standard H-beams the shop. They provide the main and stud columns the building. (TO CONCLUDED) ABOVE new State ar- mory tady, Y., has the largest welded plate girder and the largest welded arches any building the United States. (Photo courtesy General Elec- tric Co.) Py ABOVE AUNCHING tanker the “J. Van the Sun Shipyards, Chester, Pa., added the American merchant marine the world’s largest welded ship. This giant oil carrier 541 ft. in. long and has cargo capacity 6,552,000 gal. BELOW column construc- tion, made possible welding, was employed the new Lin- coln Electric Co. 200,000 sq. ft. fac- tory addition. the cross members and maximum clear from floor roof. last fact. This has long been talked inevitable step view the absurd quired the present (or old) method tin plate production. But many ob- stacles have stood the way. Now apparently most problems have been solved, for the Crucible Steel Co. started production during year, and, already stated, others are actively planning the early adop- tion this new process. re- cently published report ing steel the International Tin Re- search and Development Council lists various advantages and disadvantages. This report states part: are certain essential con- tinning process when used alter- native hot-tinning. the first the thickness the tin coating tin plate for most applications the order 0.0001 in., which about one-tenth the thickness electro- deposited nickel’ coatings produced. Thus, only very thin electro- deposited tin coatings need consid- ered. essential that electrode- posited tin coatings should have bright appearance that the ordinary hot-dipped tin coatings. This involves consideration the possibility depositing tin coatings the bright condition, alternately, the coatings are pro- duced with matte surface, the man- ner which they can given bright finish. This latter requirement involves consideration the nature the polishing process that ap- plicable exceedingly thin coating very soft metal. Finally necessary determine the protective value the thus produced comparison with that tin coatings produced hot-dipping. “In most studies the protective value electroplated coatings only necessary determine the value the coating deposited the base metal. the case steel coated with tin any process is, however, nec- essary determine the degree 32—THE IRON AGE, January 20, 1938 HIS the conclusion the review metal finishing Mr. Simonds, the first part which appeared the issue Jan. page 500. which the protective value the coat- ing affected deformation, since tinned steel seldom used almost invariably subjected severe deformation subsequent proc- esses manufacture.” Most the above considerations have been met the newly developed processes this country sponsoring the process claim that ade- quate protection provided thinner coat than previously thought necessary. Bright Nickel The process bright ing which was described consider- able detail the issue Nov. 25, 1937, AGE, came into commercial use several years ago. Nevertheless, the and widespread use this process during 1937 constitute major factor the year’s metal finishing progress. Most authorities agree nickel plating effects saving least per cent the overall cost nickel plating The bright deposits are achieved intro- ducing into the bath chemical addi- tions reduce the grain size the deposited coat. Many different baths have been developed for this purpose. Most them use sulfonated acids the aromatic series and the chief econ- omy comes through the elimination buffing operations preceding top coats chromium. The Hanson-Van Winkle-Munning Co. considers the growth the nickel plating industry the chief develop- ment the past year, but close this rates the progress the steel with finish better suited for plating “No plating establishment today can afford ignore bright ports Arnold Weisselberg, consulting Highlights the Year engineer, who recently completed tour the country studying finishing problems. cautions, “Of course some the claims are exaggerated, especially far the current den- sity Nevertheless, with comparatively little attention the aver- age shop can establish routine bright plating with small number jects. found the solution most widely used with the Harshaw solution close second. The cobalt solution unique that produces bright deposits having ductility cult obtain with other The development black nickel Zine Co. This process, said especially suitable for plating zine, has solution analysis follows: Nickel ammonium sulfate, oz. per gal.; zine sulfate, oz. per gal.; so- dium sulfocyanate, per gal.; and uses current density amp. per Color Plating Any review achievements for 1937 not only metal finishing but the wider field metallurgy should give prominence the process which Electrocolor produced. trocolor the trade name new finish for metal applied plating technique and having among its advantages accuracy specification and color reproduction metal. Now, almost any color the rainbow can produced not only once but over and over again mass production basis. Like many other recent commercial applications color plating was discovered several years ago. that time was found that alkaline solutions copper lac- tate produce cathodic deposits low current density which are highly col- ored, the color changing rainbow order through repeating time cycle. Thus the color the deposit function the thickness and thus turn the plating time. United Chro- mium, Inc., New York, exclusive licensee the process. Many other methods coloring metal emerged from i! | | | 7 > | | ted rated, with aver- lution rshaw cobalt nickel lows: per and per for but hould Elec- new ectro- mong color iction only many ations found low col- nbow cycle. Chro- oring Metal Finishing lumbia, described several these paper the American Society for Convention. these may mentioned two chemical proc- esses, one for producing dead white aluminum, and the other, black shows the use newly developed 4-wheel rotary polishing machine. dip solutions produce cop- black, brown, blue and green, and two solutions which under proper conditions give respec tively ebony black and rich brown zine base die castings. Bright Following the development bright nickel was the discov ery solution Which gives bright zinc deposits. this case the economy not much through the substitution zine for cadmium. The National Cash Reg- ister Co. gives the following tion the application bright zinc certain models its cash registers. process known Grasselli bright zine plating was installed meet the RIGHT ward stove tops are auto- matically machines this type. Production rate stove tops per hour. HERBERT SIMONDS demands for better appearance the internal parts. The solution calls for bath free from impurities with molybdenum content from one two per cent and organic bright- ening agent. The parts pass through the series Hanson-Van Winkle- Munning conveyor combination with Mercil rubber cylinders. The cleaning bath has the following three stages with intermediate rinses: (1) caustic soak, (2) electrical cleaner, and (3) pickle. Plating for time deposit from 0.00015 0.0002 in. produced. plating, the work dumped into rinsing tank and means tilting transferred through three one hot and finally hurst centrifugal dryer where parts are whirled dry. The rinsing and dumping scoops operated straight line means Chisholm- Moore monorail hoist.” scoops is cold and rinse into Tol- are Special Plates plating, although expen- still offers steel its most highly reflecting surface and offers silver silver plate protection against cor- rosion. Because these unique prop- erties the use rhodium gradually widening especially applied astro- nomical and other instruments and large airport reflectors. Baker Co., Inc., sponsors proc- ess known Rhodanize which utilizes sive, rhodium protect silverware from atmospheric tarnish. claimed that this process, which coats the silver with thin rhodium plate, there appreciable change the characteris- tic silver sheen. Handy Harmon report that they have contributed silver plating tech- nique improvement and develop- ment their pure silver anodes. This company also has developed silver solders which give high strength joints metal parts temperatures low 170 deg. These solders, the company states, contribute the proper finish refrigerators and electric apparatus. Pyrene Mfg. Co. reports recent im- provement its bright nickel process and states: “We have discovered method for controlling the physical properties the bright nickel plate will adjustment the bath. Thus comparatively simple means are able vary the throwing power, the ductility and other factors.” This company also sponsors the Pyron process for rapid deposition nickel iron alloy. During the past company reports that large quantities bus crankshafts have been reclaimed the Pyron process which builds coating the rate 0.03 in. hr. addition electroplating for ap- pearance for build-up much prog- ress has been made creating hard metallic coatings which are resistant abrasion which have other de- sired physical properties. Wherever metal mold used, production printing, thin deposit some suit- able metal such chromium may very well show increased life mold far out proportion the increased cost. Brush plating with viscous plating solutions was brought commercial application this country 1936, 34—THE IRON AGE, January 20, 1938 ° ° interior view tube enamel baking furnace under con- tion Corp. automobile industry which has been responsible for much automatic equipment also re- sponsible for this automatic curved bumper polisher. Courtesy Excelsior Tool Machine Co. but many striking improvements were made the process during 1937 fol- lowing the purchase distributing rights Nickel-Chromium Plating Corp., Chicago. This company claims have perfected harmless solutions for chromium plating. this plating was done some risk the operator’s hands. Lack standardization plated finishes the source good deal difficulty the part those who are purchasing metal accessories match prefinished products. This diffi- culty has been particularly apparent with building hardware finishes. attempt standardize these, com- parative chart showing finishes used all leading hardware manu- facturers was published recently Hardware Age. Part this chart reproduced here accompanying table. struction. Courtesy Surface Combus- The Thomas Steel Co. reports the production cold rolled steel strip electroplated the plant brass and nickel finishes. The steel strip coils drawn continuously through the plating tanks and rewound the orig- inal coil forms after plating. Subse- quent heat treating bonds the steel and the coatings, after which the coatings are polished. These prefinished strips are provided various tempers for drawing forming without surface fracture. The company sponsoring the plat- ing-in-vacuum above the Evaporated Metal Films Co., Ithaca, This company spe- cializes highly reflective mirrors and mirror surfaces and, because the technique lends itself extremely ac- curate control film thickness, the company manufactures first surface glass mirrors with any specified trans- parency for use color photography. Lacquers Have Bright Future For convenience the term “lacquer” has been broadened many manufac- turers include all the new syn- thetic and polymerized coatings. The future lacquers this new conno- tation balks the imagination, for al- most anything may happen. whole new chemistry based polymeriza- tion has come into being along with the youthful and still largely unaware plastics industry. Mix and heat to- nm wn : { gether familiar chemicals such phenol and formaldehyde the pres- ence the proper catylist and new materials under the sun Some these new materials have amazing properties and research men say one can foresee limit the physical characteristics the poly- mers that still await discovery. Many these new materials are available coatings for metal and when considered that this devel- opment independent the already established and rapidly expanding field synthetic lacquers and enamels, one may get some idea the whole drama organic coatings. Gustave Klinkenstein, technical di- rector Maas has furnished comment explaining some features this drama. states, “Significant 1937 was general tendency shorten finishing sched- ules taking advantage new types lacquers which can applied more rapidly than the older types. Thus metal parts production has been speed- up, costs have been reduced, and inventories cut down.” This shortening finishing schedules has been accomplished several ways: For finishing many kinds products, lac- quers that air-dry rapidly. are displacing enamels that have baked. The baking time enamels being reduced using enamels that can baked rapidly relatively high temperatures. Instead baking each individual undercoat separately, systems all which can baked the same time one operation, are being used. Instead using special undercoats for each final color, neutral undercoat selected this standard and then given final finish any desired color using lacquer enamels, with topcoat clear lacquer, this re- quired. Quick-drying fillers, for use heavy ma- chinery castings, are displacing those requir- ing day more dry. addition their quick-drying properties, there special reason for the increased use lacquer- enamels. China-wood (or tung) oil has heretofore been important in- gredient baking enamels, but the supply this oil reaching the United States present being greatly re- stricted the Sino-Japanese war. Certain types baking enamels can produced without the use China- wood oil, but air-drying synthetic enamels cannot made with the high- est degree hardness without this Therefore, the shortage con- tinues, the use lacquer-enamels will greatly extended. Lacquer-enamels having metallic luster have been popular year. These can supplied wide Variety pastel brilliant colors and different metallic tones. new synthetic enamel said closely resemble porcelain but requir- ing only very short baking period min. 375 deg. F.) has been developed Walker Co. Some the advantages claimed are: excel- lent adhesion one coat bare steel, brass die castings and stable colors under exposure ultra violet light. New Wrinkle Enamel The Roxalin Flexible Lacquer Co. reports the following recently devel- oped metal finishes: synthetic white baking enamel made from new base yield color purity and the same time unusual hardness. This finish said especially applicable hospital furni- ture, steel cabinets and household ap- wrinkle enamel with con- trolled predetermined pattern which said reduce rejection from around per cent less than per cent. The Midland Paint Varnish Co. has developed machinery enamel said dry hard within min. and specially valuable finish for elec- tric motors. Public utilities the past have paint for gas holders. meet this problem the Acorn Refining Co. has developed gas holder paint which, said, has been used with success the Brooklyn Union Gas Co. and other companies for painting water seals and other parts gas holders. One several companies take active interest the production plastics polymerized coatings Ault Wiborg Corp., which reports the development finish for wash- ing machines, metal furniture, and electrical appliances, which addi- tion other advantages sets rap- idly that dust free surfaces are ob- tained. Acid Proof Finishes high gloss, black baking enamel resistant per cent sulphuric acid, per cent nitric acid and similar concentrations other acids and al- kalies reported Billings-Chapin Co. This synthetic development claimed entirely new the paint field. Some the recently developed Maas Waldstein finishes are follows: 1A dust in air-drying lacquer enamel which gives blackboard finish, that is, will take chalk marks which later may removed with ordinary blackboard eraser. enamel intended for such severe ser- vice golf sticks and fishing rods and said resemble celluloid characteristics. primer for chromium. This last air-drying lacquer said overcome the usual dithculty obtaining adhesion organic coat- ynthetic lacquer which dries out min. ings chromium. Heresite Chemical Co. reports coating highly resistant alkalies and acids and intended primarily for wash- ing machine agitators and refrigera- tor shells. Its use said make unnecessary tin plate such shells agitators previous lacquer. Reports finish. ONTIAC mud- quards suspended conveyor pass tion for the final matic sequence which includes bon- derizing prepara- the rip ind ind ips for ice at- : 2 indicate life more than 420 hr. under salt spray test. Automotive Finishes Perhaps the greatest impetus the development strongly adhesive dur- able lacquers has come from the auto- motive industry and fairly safe state that every car makes use some synthetic lacquers. Yet because the variety applications any esti- mate total use extremely difficult. the conservative assumption that gallon lacquer used for every porary metal parts for protection during shipment, handling and fabrication. Other applications in- cl