The Iron Age 1938-02-24: Vol 141 Iss 8

De- Feb. San en- mill- yport, treet, South inder- unit, two- build- arage and 110 ment. shop ation, quare fire. idling now prefers the curved- bevel gears for the accuracy, and high degree efficiency performance. Hypoid gears offer qualities beside permitting pass. Large spiral bevel and gears 100” diameter are cor- generated for all purposes the ason Planing Generators. Builders Bevel Gear Machinery for Over Seventy ‘ator melt- | NCE-THEIR DESTIN When choice was made for vital parts for these 175 new Scout Observation vigilant eyes carefully scanned qualifications likely materials. And, for key parts Wheel Release and Turtle-deck Control, ELEPHANT BRAND PHOSPHOR BRONZE selected. strength and toughness; second, for long life and resistance the less enemy, Corrosion. Thus are the the Fleet’’ and the ‘‘wheels all Industry, alike, insured failures; so, are parts made permanent the right alloy the right BRAND PHOSPHOR BRONZE. some form- sheets, rods, wit rope, ingots, bushings cas ings—you have use for Phe phor Bronze. find proper alloy—call our opment Engineers; charge for their cooperative services, obligation. Stock and Price Lists, invested! Scout use castings ELE- wheel release and ot + - prow FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Bditor Art Editor Metallurgical Bditor Associate Editors JURASCHEK Consulting Hditor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco Asa ROUNTREE, JR. Toronto, Ontario Birmingham Newark, N. J St. Louis Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th St., New York, OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President FRITZ FRANK, Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANB CHARLES BAUR CARROLL BUZBY P. M. FAHRENDORE BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ‘‘Ironage, N. Y." ADVERTISING Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago H. E. Leonard, 239 W. 39th St., New York 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. 0. Box 81, Hartford, Conn. FEBRUARY 24, The Bird Dog and the Rabbits Wire Drawing Ferrous Metallurgy Pondered AIME Meeting Labor Relations Trailer Plant Electrochemical Separation Alloys Non-Metallic Elements Developments Power Drives and Handling Devices Statistics Metal Working Activity Rate Activity Capital Goods Automotive Industry Washington News NEWS CONTENTS Plant Expansion and Equipment Buying New Industrial Literature Products Advertised Just Between Two Index Advertisers Copyright 1938 by Chilton Company (Inc.) pland PHAN is, Pho Deve getting bolts you UST get the nearest distributor Bethlehem Bolts and Nuts the telephone and name the bolt that you want. (It’s rare call that does not find the item stock.) Within three hours—on rush order—your goods will their way. Bethlehem’s Lebanon Plant puts the emphasis large and varied stock. Thousands tons bolts, nuts, spikes, rivets, and specialties are constantly ready ship. 3500 standard headed and threaded items. Hundreds specialties. And these stocks can replenished the rate 10,000 tons per month necessary. BETHLEHEM STEEL COMPANY, General Offices: Bethlehem, Pa. District Offices: Albany, Atlanta, Baltimore, Boston, Bridge- port, Buffalo, Chicago, Cincinnati, Cleveland, Columbus, Dallas, Detroit, Hartford, Honolulu, Houston, Indianapolis, Johnstown, Pa., Kansas City, Mo., Los Angeles, Milwaukee, Nashville, New York, Philadelphia, Pittsburgh, Portland, Ore., St. Louis, St. Paul, Salt Lake City, San Antonio, San Francisco, Savannah, Seattle, Syracuse, Toledo, Tulsa, Washington, Wilkes-Barre, York. Export Distributor: Bethlehem Steel Export Corporation, New York. | | 4 “y j a a ee i . ~ : 24, 1938 THE IRON FEBRUARY 24, 1938 ESTABLISHED 1855 Vol. 141, No. The Bird Dog and the Rabbits NCE upon time there was hunter who depended upon his marksmanship and his bird dog for food. The bird dog would lead the hunter covey birds and after one had been shot would recover and bring his master. good bird dog, you know, must keep his thoughts his business. His mind cannot wander afield while duty and must reserve his day dreams for the kennel. Unfortunately for the hunter, his good bird dog was killed encounter with bear and had get new one. The new dog made fine appearance, had splendid bark and was much more energetic than the old one. However, had wandering mind, which was not good. When out after covey birds the new dog would take into his head chase Particularly white rabbits. could not resist them. One day, for ex- ample, just the hunter was expecting bring down fat bird for dinner, Rover happened spy nine old rabbits sitting quietly together ledge bench the hillside. flash the birds were forgotten and that was the end the hunt- ing for many days because the disturbance which Rover made throughout the woods chasing these rabbits. This was tough luck for the hunter, who had take his belt another notch and subsist gooseberries. But after time when things had quieted down the woods, thought would try Rover again. But alas, Rover spied another rabbit. was fat one and Rover had fixed idea that all fat rabbits should chased down away went and away, again, went the hunter's expectation dinner. the time the woods became quiet again, our friend the hunter was almost starving for good meal. Unfortunately his system could not stand diet rab- bits and tell the truth Rover never really caught one, although spent much time chasing them. the hunter determined try once more, this time hunt- ip. ing the bottom valley that Rover would not tempted chase fat rabbits down hill. the But reckoned wrongly unpredictable Rover. For this time, Rover deemed his duty chase thin rabbits uphill and the dinner was again postponed. The moral this story that chasing rabbits recovers birds. own, Paul, lubrication phase wire drawing still large measure empirical. should particularly appreciated that not the efficiency lubricant room tempera- tures much that the temperature actually attained the surface the die which importance. Photo courtesy Ludlum Steel Co. URING the past years large amount research wire drawing has been de- scribed print, particularly Great Britain and Germany. Rather than attempt cover the however, the author will concentrate attention the work for which has been responsible. result the fact that the mathematical treat- ment plastic deformation still its infancy, has not far been found possible treat the wire draw- ing process rigidly mathematical lines. The attempt Sachs, for in- stance, interesting is, leads one conclusion which can shown gests that the power required draw 26—THE IRON AGE, February 24, 1938 wire proportional the logarithm the ratio the original and the final areas. When the reduction area being considered subsequently, herein, will shown that experi- mentally the power not directly proportional this logarithmic func- tion, the subject, however, dealt with simpler manner, from the point view the dimensions the factors involved, can shown that the power directly proportional drawn, the speed drawing and factor which depends upon the area. character may, however, pro- found importance, although they can- WIRE RAWING ° ° not dealt with this manner. The angle and contour the die, the tem- perature which the reduction actually effected, the coefficient fric- tion between the wire and the die, the space lattice the metal alloy being drawn are all obvious impor- tance. Since, however, they are non- dimensional, they cannot sidered such analysis. also follows from this that the actual pull required directly pro- portional the elastic limit the original material the area, but independent the speed drawing. This somewhat sion will dealt with later. num- purely empirical relationships based industrial measurements in; all jus thi del wh The tem- fric- die, alloy non- con- the pro- the num- ships nents have been published from time time, and Lewis has suggested that the total horsepower required represented the following equation: 33,000 where the horsepower, the ‘tensile strength per sq. in., the rate drawing ft. per min., the original area cross section, the final cross section the wire, and variable factor, ranging per cent per cent and 1.23 per cent. opinion better relationship given the following expression: where the weight drawn tons per min., and varies from 0.12 with per cent reduction area 0.084 per cent reduction. that the power proportional A (M) (a) log a). This may compared with the Pomp., Siebel and Houdremont, which, when transformed correspond with equation III identical form. There would also appear that the power can represented such expression as, (M) (S) (a) (fR) where some non-dimensional function the reduction the wire, the logarithm the ratio the original and final areas, the reduction area per cent. Equipment Used The apparatus used for the high- speed drawing consists rigid arm girder section pivoted ball bear- ings about its center. one end the die fastened straps and bolts, the Wire passing through small hole drilled the arm for that purpose. The pull the wire the die tends swing this arm forward one end and counter-balance this movement there is, the opposite end the arm, piston working cylinder into which compressed air allowed enter. suitable ad- entrance and exit valves this piston can made restore the arm exactly its original position, and two electric lamps connected delicately adjusted contacts show exact balance has been at- tained. The pressure the cylinder then measure the actual pull the wire. The apparatus cali- brated attaching standard spring balance between the drum and the die. system gears and rheostats the speed drawing may varied from about 0.1 600 ft. per min., hp. shunt-wound d.c. motor normally running speed 380 r.p.m. being employed provide the necessary power. has already been pointed out that considerations the dimensions the factors involved suggest that the actual pull required draw wire independent the speed which the drawing carried out. the rela- tionship between the pull and the speed drawing for per cent nickel- silver shown, however, will wire drawing process it- self, aside from the effect the process the mechanical properties the wire, has been given considerable attention some prominent engineers. Rather than sketch over the en- tire field inquiry, however, the author, who himself skilled investigator, has herein reviewed much his original work the mechanics wire drawing, and has most interesting manner correlated his work with the pub- lished data other investiga- tors. This article was presented originally lecture Birming- ham, England, before the Mid- land Metallurgical Societies. seen that the very low speeds em- ployed the prediction that the pull independent the speed completely falsified, the markedly the speed drawing raised. If, however, higher speeds— say ft. per min. above—are then the tension needed effect given reduction for given material quite independent the speed which the wire drawn. These re- sults have been obtained with tungsten carbide dies semi-angle, but identical result obtained with dies other contours. With steel dies there some slight tendency for the pull required rise the speed increased, but this probably ex- plicable the ground increased frictional loss. For all practical pur- poses, except possibly the case low-speed draw-bench work, will seen that the pull independent the speed drawing, although course the total power consumed will directly proportional that factor. will appreciated that research which carried out only very low speeds drawing, as, for instance, tensile testing machine, may give results which are radically different from those obtained high speeds under industrial conditions. This dan- ger relying research low speeds will again emphasized when attention being paid the effect rotating the die during the drawing. Since the pull required remains un- changed under the conditions these experiments when the speed draw- ing exceeds about ft. per min., there for experimental purposes speeds, and for purposes economy ft. per min. the speed which has normally been adopted this Practical confirmation the con- clusion just reached that the pull re- quired, except very low speeds, independent the speed drawing, has been obtained both fine wire and thick rods for bolts, any rate speeds well over 1000 ft. per min. view this fact, curious that some instances comparatively low speeds drawing the order perhaps 300 ft. per min. are still being employed the drawing Justification for this the ground that age- embrittlement wire increases the speed drawing case, justification for determine whether the age-embrittle- ment does depend the speed drawing, investigation has been carbon steel drawn rates varying from about 600 ft. per min. far, any rate, change the ten- sile strength concerned, differ- ence whatever could detected the ageing characteristics the slow- and quickly-drawn wire. ap- preciated, however, that the tensile strength not itself always adequate measure such embrittle- ment, and further work this direc- tion would justified. The conclusions drawn from the dimensional analysis are agree- ment, far the relationship the elastic limit and the tension re- quired effect given reduction THE IRON AGE, February 24, 1938—27 ‘ee 4 through die standard contour concerned. The difficulty, however, determining the elastic limit wires makes the more justifiable in- quire what extent similar rela- tionship will hold the maximum stress taken measure the mechanical properties the wire drawn. will seen that al- though the scatter the points for the maximum stress curve distinct- greater than that for the elastic limit, clear that, any rate close approximation, the maximum stress the original wire again measure the pull required. Brown and Giraud, among others, have investigated the influence the reduction area pass upon the work done, and each case have shown that the pull required linear function the reduction area. Both sets measurements were, however, made low speeds drawing and somewhat similar materials, and appeared well dis- cover how far the same relationship would hold for other metals and for the higher speeds drawing. For 70-30 brass, nickel, cupro-nickel and nickel-silver, the relationship has been shown obtain reduc- tions per cent any rate. the case steels, however, the reduction area-tension curve re- mains linear only until re- duction something the order cent, the pull required for larger reductions being would expected. How deviation the case the steel due the increased heat generated and the rise temperature both wire and lubricant cannot present determined, but clear that for the non-ferrous materials over very wide range reduction and for the steels any rate about per cent, the tension with the reduction area. was pointed out, the mathemati- cal treatment suggests that the pull should directly proportional the logarithm the ratio the original and the final area cross-section. This is, however, not accordance with experiment. The importance the angle and the contour the die successful wire drawing needs emphasis. Using carbide dies—and should pointed out here that, unless the con- trary stated, all the experiments described herein were such dies—the results may sum- marized saying that for non-fer- rous metals the minimum tension required with semi-angle about 28—THE IRON AGE, February 24, 1938 deg. Smaller angles lead rapidly increased tension, sumably increased frictional losses, the increase with higher angles being much less pronounced. has been confirmed for reductions area varying from per cent per pass, for wide range non- ferrous metals and alloys, for good and bad lubricants, and for material the annealed and the cold- drawn condition. The results for steel are much less simple, succession maximum and minimum lowing each other over the whole ex- tent the curve. first sight, such irregularities would put down experimental error, but repeated tests with repolished dies range steels varying carbon content have satisfied the author that the fluctua- tions have real existence. This confirmed the fact that, using steel dies, firm wire-drawers has inde- pendently carried out vestigation and found similar maxima and minima. the moment quite impossible offer any explanation these results. connection with the actual drawing wire there may, however, occasions when this not the most satisfactory. There is, for instance, some evidence that the case hot-rolled rod with rough surface, distinctly higher angle advantage the prelimi- nary breaking-down treatment. Sec- ondly, the case small reductions the necessity for the use ade- quately long bearing withstand the pressure requires smaller die angle than that which has been found the best for reductions per cent over. The extensive use the so-called “radial-taper” bearing, particularly makes desirable compare this contour with the plain conical dies far examined. all cases, both for ferrous and for non-ferrous metals, has been found that the power con- sumption with the radial bearing ex- ceeds, and sometimes exceeds consid- erably, that required for the plain conical die. The difference the power consumption decreases, how- ever, the reduction area becomes greater and the metal being drawn becomes harder. the case “Post Office” bronze, for instance, the power consumed effecting per cent reduction through radial-taper die was per cent higher than that through die straight taper deg. semi-angle. the case Monel metal the difference for the same re- duction area had fallen per cent, and for reduction per cent had been reduced about per cent. The author has, however, come across single instance which wire could drawn through radial-taper die without requiring greater tension than needed for plain cone with semi-angle deg. the case carbide dies any rate, the power required depends not inconsiderable extent the perfection the polish the bear- ing, and variations over per cent have been obtained for dies the same contour according the preparation was more less skiliul. every case which has been ex- amined, both with good and bad lubri- cants, the pull necessary effect given reduction area less with carbide than with steel die the same contour. When carbide dies are compared with diamond dies, has been shown that the pull required with the latter distinctly less than with the carbide die. example, for 80-20 cupro-nickel, 0.044 in. diameter, the pull required effect per cent reduction area was 44.5 lb. with the carbide die com- pared with the diamond die, the same “Germ oil” lubricant being used each case. Despite the great practical tance the proper wire, very little published information this aspect wire-drawing avail- able. The complicated nature the problem will appreciated, the moment quite impossible explain curves, which have been ob- tained both for ferrous ferrous materials and using range reductions area. one result this research, tended reference may made. coil Post Office bronze immediately removal from the block was carefully disentangled, when consisted two distinct helices, the angles which were right angles each other. One helix, which consisted the first eight turns the coil, lay nicely the floor whereas the remainder could arranged without the turns over- lapping each other horizontal string. would almost appear the first few turns the coil were this case the whole cause the trouble. This portion the coil was found correspond with that part the wire which spirals down from the top the bottom the block the commencement drawing, and found that the conditions apply other cases, might, some measure any rate. I l 0 n a ex an as per per igh ing for nds the per the ex- bri- vith the are has with vith for ffect was die, eing |por- vire, vail- the ob- non- wide one coil fully two first could over- the was irt the itions rate. design the block such way that the jaws for gripping the wire are the bottom instead of, usual, the top the block. Importance Lubricant amount work has been done lubrication wire drawing, the num- ber fundamental facts which have been definitely established Lubrication process large measure em- pirical. One the most important all the facts which have emerged that the lubrication is, all probability, the type. This offers expla- nation the experi- mental result that the fatty acid apprecia- bly reduces the fric- tion the pull required. under determining exact- the pull required draw wire makes the more desirable inquire whether there exists any sim- ple form appara- tus which an, any rate, approxi- mate evaluation the efficiency lubricant can de- termined. will appreciated, how- ever, that not the efficiency the lubricant room temperatures much that the temperature actually attained the surface the die which impor- tance. the temperature raised, the pull falls, first fairly rapidly, and then more slowly, until, tempera- ture about 170 deg., sudden in- Crease the tension occurs. This increase presumably due cant, after which the tension required and the drawing distinctly erratic. For all the lubricating materials ex- amined the frictional loss decreases the temperature raised, fact which little difficult reconcile with the elaborate precautions which are sometimes taken cool the There obvious reason why tung- sten carbide dies should wear more rapidly elevated temperatures than they room temperature, particu- larly view the fact that such dies are successfully employed for drawing tungsten wire 1300 deg. Rapid fluctuations the temperature such dies, however, must avoided far possible since there other- wise risk superficial dis- integration due the thermal stresses which are set up. Reference may, however, made one material which has given par- ticularly interesting and unexpected results. Water room temperature particularly bad “lubricant.” the temperature raised its efficiency improves considerably, and temper- atures just below its boiling point water almost efficient really good soap. Further, the surface the wire drawn with nearly boiling water particularly good and suitable for subsequent such processes The importance adequately an- choring the lubricant the surface the wire will, view the boun- dary nature the film, readily appreciated. now generally ac- cepted that the value the “water coat” the drawing steel lies its ability absorb and retain stable film the soap. The exten- sion the use such film non- ferrous wires possibility which well worth exploring. Another type coat which deserves mention that soft metal con- junction, course, with suitable lubri- cant. The coppering process too well known need em- phasizing here, but other metals, and particular lead, have been tried with con- siderable success. the drawing aus- tenitic stainless steel tubes and wire the process, which lead coating employed, has been used with suc- cess. One aspect the cant, which times very con- siderable practical importance, skin troubles which operators may suffer through its use. Cer- tain types soap are particularly like- cause trouble this kind, and there are fairly good grounds for the be- lief that soaps, made from fat including large proportion cocoanut palm- kernel oils, reacting those possessing idiosyncrasy this complaint, are particularly dan- gerous. The author has been informed that the trouble may eliminated if, prior work, the hands are rubbed well with mixture unsalted lard and per cent boric acid. Rotating Dies Although rotating dies have been employed very limited extent, presumably with view increas- ing the life the die distributing the wear evenly possible over the whole surface and thus improv- the surface the materials, the (CONCLUDED PAGE 82) THE IRON AGE, February 24, 1938—29 £ “ A . é a . F : d 4 4 si a 5 : a 4 4 4 ‘ ‘ i Ferrous ORE than 2400 engineers, out 10,000, gathered the four corners the earth last week the Engineering Societies Building, New York, the American Institute Mining and Metallurgical Engi- neers swung through its 148th meet- ing. There was plenty attraction, what with elaborate technical pro- gram titillate the metallurgist, phy- sicist, geologist and the educator, all which was ably leavened with well developed social program reach- ing climax the annual dinner and dance, the Hotel Waldorf-Astoria, Wednesday evening, Feb. 16. With Rolland Craten Allen, presi- dent the Institute during 1937, master, the members attending the dinner were introduced Daniel Cowan Jackling, president the Utah Copper Co., and the Institute presi- dent for 1938. Subsequently, num- ber honors were conferred members who had served the Institute with credit. The James Douglas Medal, awarded for distinguished achievement lurgy, went Hardinge, presi- dent Hardinge Co., manufacturers mining and milling equipment; the Anthony Lucas Medal, for achieve- ment improving the technique and practice finding producing pe- troleum, was awarded Doherty, president Cities Service Co.; the 1938 honorary membership was presented John Reyn- ders, one the most famous the world’s bridge builders, and for many years professional adviser steel works and banking institutions; the recipients the Robert Woolston Hunt Award for 1938 were Thomas Washburn and John Nead, both Inland Steel Co., co-authors paper presented last year dealing with the structure rimmed-steel and for his meritorious study the 30—THE IRON AGE, February 24, 1938 Meta performance and selection refrac- tories for blast furnace linings, Roy Lindgren, Wisconsin Steel Works, was awarded the John- son Jr. Award. New members the Legion Honor, that those men who have been the rolls for years more, also were introduced the banquet. The ten more members who achieved this distinction for the first time this year are: Henry Conant, Karl Eilers, William Gerhauser, David Jacobus, Henry Louis, Ellison Means, Erskine Ramsay, Rickard, Olof Wenstrom, and William Wilkin- son. the many hundreds technical papers presented meeting rooms the Engineering Societies Building, from Monday Friday last week, space requirements necessitate that only few treated herein. The sessions blast furnaces and cast iron, Tuesday morning, ticularly interesting, dealing they did with the “Efficiency the Blast the United States Steel Corp.; “Pres- sure Operation the Pig Iron Blast Furnace,” Julian Avery, Arthur Little, Inc.; and “Relative Desulphurizing Powers Blast Fur- the United States Bureau Mines. Blast Furnace Operation his paper blast furnace ef- ficiency, Austin pointed out that process the smelting iron the blast furnace, there obviously single method calculating efficiency which gives complete appraisal the performance the furnace all its several functions; such compre- hensive view required evalu- ate producing ability and manufac- turing costs for given furnace obtained only considering group efficiencies, each which measures lurgy Pondered Engineering Societies Bulges With Rec Members Gather tribute Honors, and Technical the performance the furnace from specific point view. For instance, there the rate consumption coke per ton iron produced, which probably the most frequently con- sidered, and certainly one the most important, the group; there the efficiency recovery iron charged; and there is, some re- spects related the former two, yet other ways, independent from either, the efficiency utilization energy, both chemical and thermal. each these cases, the calculation can made the basis the actual input material energy, may based upon comparison with the minimum amount material energy which would required “perfect” furnace, that is, imagi- nary ideal furnace analogous the perfect steam engine used thermo- dynamic calculations, operating under optimum conditions. Moreover, the furnace itself can either apparatus for smelt- ing iron, taking somewhat less common point view, gas producer yielding iron and slag by- products. Some these efficiencies are more useful than others, yet all are instructive, according Mr. Austin; for knowledge them not only leads good engineering prac- tice from the standpoint control, but also discloses limits possible im- dicates the lines along which improve- 7 q & Ci Nn. ni 148th Meeting Building, New York, ord Attendance Elect Officers, Dis- Assimilate Over 250 Papers. ment most likely profitable. Estimates some these efficiencies have appeared from time time the literature, but many them are open objection; because, according Mr. Austin, they are based data uncertain accuracy because they have been calculated without due re- gard the thermodynamic principles involved. Moreover, far Mr. Austin aware, general survey the blast furnace comparing its per- formance all the aspects mentioned has been made. Therefore, his elaborate paper, Mr. Austin’s purpose consider and compare these several efficien- cies calculated from the most re- liable data now available. There attempt supply detailed calculations every instance, but the aim rather present point view, chiefly regards the performance perfect furnace, with only occasional resort numerical values, leaving detailed calculations carried out each investigator for the cases which may interested. using established chemical and physical principles set the performance perfect fur- nace, Mr. Austin really sets par value, bogy, with reference which the performance real fur- nace can compared. This establishment perfect fur- nace developed considerable de- tail Mr. Austin, with the help several tables and charts. ticular, however, the consideration the material and thermal efficiencies the blast furnace considered both smelter and gas producer lead the author the following con- (1) blast furnace producing the usual grades low silicon pig iron, the coke consumption deter- mined the demand for carbon reducing agent rather than the de- mand for fuel, for the heat liberated combustion the carbon neces- sary give the proper quantity reducing gas, is, together with the heat brought the hot blast, suf- ficient meet the heat requirements the furnace. The general heat bal- ance well the distribution the heat generated between hearth (melt- ing) and shaft (reducing) zones controlled within limits adjusting the temperature and volume the hot blast. the furnace producing high silicon foundry iron, ferromanganese ferrosilicon, the heat requirement per ton product considerably greater than for the ordinary pig iron grades, and the coke consumption may fixed primarily the demand for carbon fuel, although this may not always true since the CO/CO, ratio equilibrium also raised such cases. (2) The amount coke required for giving proper reducing gas fixed chiefly the equilibrium condi- tions the reduction FeO Fe, and since the equilibrium changes with temperature the coke consump- tion likewise influenced. The higher the temperature which this stage the reduction carried out the higher the coke consumption. (3) Preliminary calculations, tak- ing account the chemical equilibri- um, indicate that blast furnace using 1800 coke per ton pig over per cent efficient the utilization coke. (4) The thermal efficiency the blast furnace taken smelter high, being most cases better than per cent. (5) Taking the blast furnace gas producer, the maximum conver- sion coke carbon monoxide must less than that gas producer, the relative efficiency being the ideal case about per cent. actual blast furnace usually operates close its own ideal efficiency producer, however. (6) The hot gas efficiency the blast furnace, regarded gas pro- ducer, high, being the order magnitude per cent. (7) These conclusions all indicate that the blast furnace now operated relatively efficient apparatus com- pared other chemical metal- lurgical equipment. While improve- ments design, control opera- tion give uniform product, and reducing heat loss radiation and conduction are expected, there reduction coke consumption under that achieved the best modern practice. also clear that any process designed compete with the blast furnace must, like the blast fur- nace, show high efficiency both have any chance success com- petition with the blast furnace the steel producing districts, where metal- lurgical fuel, suitable for blast furnace use, commercially available. Pressure Operation Blast Furnace broad sense, the suggestion pressure operation the pig iron blast furnace not new, for operation un- der moderately increased overall pres- sure was suggested early 1871, less authority than Henry Bessemer. But the reasons set forth that time for the use higher overall pressure were evidently in- adequate, because there appears record that Bessemer’s suggestion THE IRON AGE, February 24, n “9 n in 1eS all Ar. not ac- ; im- in- ve- JOHN VAN WICHEREN REYNDERS, awarded the honorary membership the Mr. Reynders known for his outstanding ability adviser steel companies, and, also, for his skill putting steel practical use bridges and other structures. was ever put trial. any event, since blast furnace literature least the past years singularly lacking mention pressure opera- tion, the subject revived Julian real and significance. Mr. Avery his paper entitled “Pressure Operation the Pig Iron Blast Fur- nace and the Problem Solution Loss,” pointed out that most metal- lurgists and engineers consider that the primary function the pig iron blast furnace produce pig iron the lowest possible cost, aad that its function gas producer should subordinated this primary purpose. During the past ten years more, im- provements blast furnace technique and economy have, fact, been di- rected primarily increasing efficien- the use the reduciag power gases produced combustion coke the tuyeres, reduce iron ore within the furnace. The net overall result decrease the fuel value the top gas per unit volume, and per ton pig iron, which evidently more than offset value the corol- lary saving coke and the possibility increased furnace capacity, for otherwise there would point making such improvements. While progress has been made this direction, Mr. Avery’s paper points out that there another ap- 32—THE IRON AGE, February 24, 1938 proach the problem increasing the chemical and thermal efficiency the blast furnace its primary role pig iron smelter, which appears offer possibilities improvement overall economy different order magnitude than results thus far ob- tained the use other expedients. The present argument based large part upon the hypothesis that the efficiency and economics pig iron smelting are seriously and adversely affected the phenomenon known loss,” and that the problem solution loss can at- tacked increasing the overall pres- sure, the “top under which the furnace operated, indicated that pressure operation may also expected result concom- itant benefits which may summed generally improved operating conditions, together with substantial saving fuel and/or substantial in- crease furnace capacity. Even though Mr. paper covered many the ramifications the problem, could not cover ade- quate detail even mention all the factors involved the comparative merits pressure operation. The primary purpose the paper was stimulate discussion this important subject, leaving for later consideration and research problems which are bound arise, for instance the amount pressure required bring out given result under given condi- tions, the effect pressure upon de- composition the upper part the stack, the amount blast power required, the amount power which can economically recovered expanding the top gases, and the overall economies pressure opera- tion. course, the author studied such factors far possible without adequate data. appears that very substantial benefits may obtained using top pressure the order from gage, and that con- siderably higher top mately may found desirable; that the pressures required need not seri- ously affect decomposition CO; that additional blast power required may most cases recovered expanding the top gases; that furnace production may very substantially increased doubled pressure operation; and that combined overall fuel economy and savings fixed charges due increased capacity ultimately expected substantially exceed per ton pig iron produced. This paper Mr. Avery stimulated considerable discussion the effect that pressure operation offers virgin field for development blast furnace design and operating technique, which shows promise handsome reward for the expense and effort which must expended substantial results are Desulphurizing Powers Slags paper presented two years ago the relative desulphurizing powers blast furnace slags, the method de- veloped for the measurement this desulphurizing power slags was de- scribed and data were presented cov- ering the range likely slags con- taining per cent MgO. paper Tuesday morning, Mr. Hol- brook extended the range this work per cent MgO, and the effect tem- perature per cent and per cent MgO slags over the range 1475 deg. 1525 deg. included. The meth- used was that described the pre- THOMAS WASHBURN assistant metallurgist and chief metallurgist, the Robert Woolston Hunt Award for their structure rimmed vious paper except that some the temperature measurements were made with noble-metal thermocouple in- stead tungsten-graphite thermo- couple. Twelve-gram charges 0.8 per cent sulphur-metal and charges slag were subjected temperature. The charges were an- alyzed for sulphur content. For pur- poses comparison, desulphurizing power defined the ratio the . . 7 4 4 al “= | > — ace ich ard are the made in- ribed an- pur- the percentage sulphur found the slag that found the metal. Six slag and metal charges were made co- electrode graphite rod. One slag and metal charge was used control means which adjustment the desulphurization value could made for small variations tempera- ture and other factors. convenient presentation the data, the slags are arranged groups each which one the four main slag components constant. Thus, the per cent MgO slags are presented separately from those containing per cent MgO. making the studies desulphur- ization, temperature 1500 deg. has been taken one the standard conditions. This temperature with- the range commonly observed blast furnace operation, but other tem- peratures obtain and knowledge the effect temperature desul- JOHN HUNTER NEAD respectively, Inland Steel Co., awarded presented last year dealing with the steel ingots. phurization slags desirable, ac- cording Mr. Holbrook. tematic survey was made two tem- peratures other than 1500 deg. namely 1475 deg. and 1525 deg. the previous investigation, was found the current instance that temperature rise results in- crease the desulphurizing power all slags, but the increase greatest toward the area viscous highly basic slags. Except these slags, the effect temperature change seems uniform. Increased Basicity Improves Desulphurization The data presented Mr. Hol- brook, together with those previously reported, show the comparative desul- phurizing character 1500 deg. practically any possible slag composi- tion within range approximately and per cent bases (CaO and, addition, scat- tered compositions outside these ranges. The generally accepted fact that in- creased basicity improves desulphur- ization corroborated, but the data show that for given MgO content there optimum basicity beyond which the slags become very poor de- sulphurizers. The isodesulphurization contours show that the composition critically related desulphurization optimum and higher basicities and less the range less basic slags. general, the data show that slight improvement may expected from the replacement amount SiO, like amount MgO for CaO cause slight decreases desulphurization. Neither these statements holds true, however, the areas optimum composition. the other hand, replacement cording Mr. Holbrook, shows com- paratively large effects most the composition areas. Increasing the temperature from 1475 deg 1525 deg. was found double the desulphurization ratio most the ordinary blast furnace slag compositions. The magnitude the change desulphurizing power that may ex- pected from any given change the composition slag from any shown diagrams presented Mr. paper. Rimming Steel Ingots All Thursday morning was de- voted session steel making and steel ingots. One interesting paper this group dealt with the “Evolution Gases From Rimming Steel In- gots,” and was presented Cutcheon, Armco, and John Chip- man, the Massachusetts Institute Technology. very large extent the quality mild steel ingot determined the manner which poured into the ingot mold and its behavior dur- DANIEL COWAN JACKLING, president the Utah Copper Co., and president the American Institute Mining and Metallurgical Engineers for 1938. ing the first few minutes after has been poured. The formation the solid rim metal around the periph- ery the mold, the effervescent action the liquid steel within this solidified rim and the upward down- ward movement the metal level are indications what going be- neath the surface the liquid metal, especially the interface which solidification occurs. Observation this “rimming action” enables ex- perienced observer predict the thickness the sound skin the in- got and the location and extent cavities “blowholes” caused en- trapment gases. The control rimming action the hands skill- ful steel pourer vital part the control quality mild steel sheet, and the behavior the liquid steel during the rimming period useful criterion the melting and refining practices employed the open hearth. McCutcheon and Chipman their paper pointed out that the behavior rimming steel during solidification depends primarily upon the evolution gases from the molten metal and therefore problem considerable interest determine the nature and amount the gases evolved. num- ber attempts determine either the amount the analysis the evolved gases have been reported other authors. Klinger, 1925, an- alyzed the gases extracted from rim- ming, semi-killed and killed steel in- THE IRON AGE, February 24, 1938—33 a eph de- this de- : ork em- ‘ ‘ent q leg. eth- irgist, their mmed gots and found that the chief constitu- ent the rimming gas was carbon monoxide. The relatively large amounts nitrogen reported his first few samples may due in- complete removal air from the gas collecting mechanism, according the authors. McCune reported similar studies rimming ingots from which surprisingly large proportions ni- trogen and hydrogen were evolved. Ameen and Willners determined both the amount and composition gases extracted from unkilled ingots with the aid diminished pressure. Their ingots weighed only 176 and ap- parently were solid within two three minutes, that their results are entirely inapplicable studies rim- ming behavior commercial ingots. McCutcheon and Chipman their paper describe the method they devel- oped collect gases, method gas analysis and interpretation results, using all cases 39-in. ingots weighing 11,300 12,000 The gas samples analyzed modern Bur- rell analyzer, showed that the prin- cipal gas was carbon monoxide, with which were associated smaller amounts carbon dioxide, hydrogen and nitrogen. The presence oxygen any sample was considered evidence leakage and very few samples showed more than 0.1 per cent this gas. Small amounts unidentified hydrocarbon were found many the samples. This was reported methane, although the authors were not positive that was accurately identified such. their studies, the authors ex- amined rimming ingots, and the data secured are assembled abridged form herein Three four gas analyses scattered through the evolution period are shown for each ingot. tabulating the data attempt has been made the authors select analyses which are representative the much larger total number analyses obtained and exclude results involving uncer- tainties arising from faulty handling the occurrence more than 0.2 per cent oxygen. The rate data have in- dicated that about min. after the mold filled one-half the total gas has been evolved. The analysis gas sample during this interval should represent approximately the mean gas analysis for the ingot. Included the table column showing the duration the gas evolu- tion. was noted general that this longer period than ordinary ingot remains open. The neighboring ingots had always solidified across the top before evolution the covered 34—THE IRON AGE, February 24, 1938 ingot had ceased. This difference probably due large measure the insulating effect the hood which simply causes the surface the ingot solidify more slowly. column also included show the total gas evolved from those ingots which satisfactory measurement was obtained. This total includes the ROY LINDGREN, superintendent blast furnaces for Wis- consin Steel Works, recipient the Johnson, Jr. Award, for his meritorious study the performance and selection refractories for blast furnace linings. amount actually measured plus the estimated volume evolved between the completion pouring and the begin- ning the measurement. The uncer- tainty this estimate fairly large. The data provided basis for esti- mating the amount gas evolved while the mold being filled. This volume has been roughly estimated from the drop carbon between ladle and mold and appears the or- Metalloids Rimmed Steel second paper the Thursday morning session, entitled “Distribu- tion Metalloids Rimmed Steel Ingots,” and presented Halley and Washburn, metal- lurgists with Inland Steel Co., also deserves particular attention because throws additional light the metal- lurgy rimmed steel, subject that has received particularly little atten- tion view the fact that rimming steels represent large proportion the amount plain carbon steel made. their paper, the authors present particularly able explanation what rimming steel is, explanation which worth repeating here: ming steels derive their name from their action during solidification the molds. result incomplete deoxidation, gas evolved during freezing, and the metal has char- acteristic rolling action. The metal rises along the mold walls and de- scends the center the ingot. This action keeps the top the ingot open and the advancing rim solid metal can seen. The rim grows until the rolling action insufficient prevent the top the ingot from freezing, until the action stopped capping the ingot with heavy plate. The violence the reaction and its characteristics, such growth drop the molds, are determined the composition, the furnace practice, and the deoxidation the ladle and the molds.” The investigation Haley and Washburn was made determine accurately the distribu- tion carbon, manganese, and sul- phur normal rimmed ingots and the general distribution other common elements present. The study included some work the effect pouring conditions and furnace practice the distribution, though there still much done this direction. Marked differences were found the authors the distribution car- bon, manganese and sulphur, which indicates different mechanisms con- trolling the distribution the three elements. The reaction carbon with ferrous oxide the steel the most important reaction that occurs during rimming and would expected control the distribution carbon the rim zone. The decrease carbon across the rim near the top the ingot indicates that the concentration ferrous oxide the liquid steel the solid liquid interface increases the rimming proceeds. Near the bot- tom the ingot the pressure exerted the liquid steel high enough nearly suppress the reaction between carbon and ferrous oxide. The pres- ence the primary dicates that some gas evolved but the uniform carbon content across the bottom the ingot shows that little carbon removed. probable that the gas evolution slow that the | ‘ ‘ ‘ ‘ = 4 a c a p n p n a p n bubbles are trapped between the grow- ing dendrites. the core zone the distribution similar that found killed steel and controlled the rate cooling, the distance between the liquidus and solidus the iron- carbon system, and the rate dif- fusion carbon solid iron. The average decrease carbon between the ladle and the solid ingot about 0.02 per cent. The concentration manganese shows drop across the rim zone similar that shown carbon, which probably the result the same change concentration ferrous oxide during rimming. the prod- uct the reaction manganese and ferrous oxide solid rather than gas, the reaction affected little pressure, and the distribution the rim zone changes little between the top and bottom the ingot. The manganese oxide formed carried the top the ingot the rising stream molten steel and gas during the rimming and combines with fer- rous oxide form the slag found the top the ingot. Manganese also removed with sulphur manga- nese sulphide. When the ingot cap- ped the distribution manganese determined the factors that control distribution killed steel and the action the remaining manganese oxide. the particles manganese oxide have low density, they will rise until the steel the core zone freezes. This process removes manganese from the bottom the core zone and re- sults the low-analysis area shown the distribution curves. The distribution sulphur not affected the ferrous oxide content the molten metal, according the authors, therefore there virtually cha