The Iron Age 1938-04-07: Vol 141 Iss 14

@ WARREN, equipment tin — detective was ever more thorough running down criminal than are the “R-Men” (Republic Metallurgists) ferreting out and preventing crimes industry. Day after day they employ the most scientific means availa- ble battling abrasion, corrosion, oxidation, fatigue, shock and strain—the extortionists industry—the murderers machin- ery. Case after case goes into their record files add their experience and pare them for similar tasks the And time after time, their final report shows savings cost improvement product for some user Why not put the “R-Men” work your plant your product? There will obligation. Republic Steel Corpo- ration, Alloy Steel Massiilon, Ohio—General Ohio. 2—THE IRON AGE, April 1938 THE IRON AGE, published every Thursday the CHILTON CO. (INC.). Publication Office, Chestnut 56th Philadelphia, and Executive Offices, 239 39th St., New York, class November 1932, the Office Philadelphia Act March 1879. $6.00 year S., Canada $8.50, Foreign $1200. Vol. 141, No. 14. at. oft. 3 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 | Cincinnati FRAZAR Boston Hamburg, Germany MEYER CHARLES POST Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Leroy ALLISON Roy Newark. VN J Rt. Lawie TURNER Buffalo Owned and Published by CHILTON COMPANY Publication Office Chestnut and 56th Sts.. Philadelphia, Pa. and Executive Offices 239 West 39th New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, = WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS CHARLES BAUR CARROLL BUZBY M. FAHRENDORF BAUR, General Advertising DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00, Can- ada, $8.50; Foreign, $12.00 a year. Single copy, cents. Cable Address, ‘‘Tronage, N. Y."' ADVERTISING STAFF Emerson Findley, 621 Union Bidg., 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, IP. 0. Box 81. Hartford, Conn Contents APRIL Industry Works for Workers Kicking Soap Box from Under the Demagoque Brass and Aluminum Castings Modernizing Malleable Foundry Foundrymen Argue Cupola Problems New Developments Cutters, Tools and Gages Characteristics Industrial Transmission Belting Statistics Metal Working Activity Automotive Industry Rate Activity Capital Goods Washington News NEWS CONTENTS Plant Expansion and Equipment Buying New Literature Just Between Two Products Advertised Index Advertisers Copyright 1938 Chilton Company 120 150 158 184 | j | | vee > y 9 | ‘ial let id takes mighty husky steel stand the heavy punish- ment battering jobs under the lash powerful pneumatic hammers. Bethlehem Omega Tool Steel takes these jobs its stride, not fazed abusive service that would quickly break down any but super-shock-resistant tool steel. Omega has unique combination high strength and great toughness that makes natural for tools subjected drastic, repeated impacts. Quenching oil 1600 deg. and tempering 400 deg. give Omega Rockwell hardness C59. Tempering slightly higher temperatures BETHLEHEM STEEL further increases toughness without causing any reduction impact resistance. Omega primarily oil-hardening steel and all tricate parts should quenched oil. Less parts and tools, however, are often satisfactorily Either treatment develops the combination high strength and toughness characteristic Steel. The complete range Bethlehem Tool Steels provides material for every job handled tool steel shop, mill mine. q | | | THE IRON AGE ... ESTABLISHED 1855 Vol. 141, No. Industry Works for Workers the fragile material which made, the soap box has supported lot people. Quite number vociferous demagogues, po- litical and otherwise, still make remunerative living standing upon it. has been particularly profitable during the past few years. man soap box can always collect crowd, matter what sort crack- pot philosophy, religion, health doctrine politics handing out. And al- ways finds plenty takers for his wares. this respect the same advantage taken human gullibility was taken the old-school itinerant quack who toured the country selling colored water guaranteed cure all the ills man beast. The quack medicine man away with partly because put good show and partly because there was authority hand with dependable facts with which contradict his wild claims. some dependable doctor, esteemed the community, had been present tell the audience that the quack's concoc- tion was valueless perhaps even harmful—and prove it—doubtless the sales would have dwindled considerably. the article which follows this page, Young kicks the soap box from under the demagogue who has been selling the poisonous nostrum class hatred American workers. These nosey, noisome, and noisy parasites the body politic have been preaching high places and low that the employee being increas- ingly ground beneath the heel rapacious and hard hearted monster known the employer. They have had plenty takers, largely because the facts dis- prove their assertions were not forthcoming. Mr. Young controverts these assertions through the unimpeachable authority Government survey conducted the Department Commerce under the auspices the present Administration and published through the Government Printing Office 1936. Under the circumstances this cannot dismissed propaganda the employing class, the Republican party the Liberty League. urge all our readers carefully study the facts which Mr. Young pre- sents and broadcast them widely possible the interest more united front employees and employers the coming march progress. APRIL , 4 the Soap every section this country, whether Savannah Seattle, Dallas Detroit—the same ques- tion continuously asked, and general rule goes swered. hear this question every farmhouse, every working home, the home every consumer, and that takes most us, question that must answered “National Income the United States, ment Commerce. Obtainable from Government Printing Office, Wash- ington, Price 25c. IGHTY cent our entire American manufacturing industry, buildings, equipment and land being operated for the sole benefit the em- ployeeswhowork therein. remain, and peacetul progress insured. the charge true that has been hurled from thousand platforms weekly throughout the United States and the average people the country get practically nothing, and the em- ployers, the bankers, the bondholders and stockholders get practically all our national income?” might well face facts, for sooner later will have face them anyway. These charges have been made, they have been published literally millions pamphlets, book- From Under lets and newspapers, They have been shouted thousands soap box orators. They have been hurled upon and yet the astonishing fact that there have been very few at- tempts made answer those devastat- ing charges. Let’s follow this line reasoning little further. the condition tually does exist that the demagogues and radicals say and think exists, live under intolerable economic system—the radicals are the patriots, and the so-called sound thinking people copies the above illustration, with short explanatory request our Reader IRON AGE, April 1938 | ° ° ° | li- ict TA) the Demagogue this country are the men who are dead wrong. the economic condi- tions that the demagogues and the extreme radicals say exist not exist, the business leaders, the civic leaders, the leaders all organized groups every community should step out and definitely and vigorously not only deny the charge, but establish the Now the business man this coun- try, and the civic leader well, must admit that knew the answers all these charges majority them, has hidden that fact remark ably well. not alone the working man who has listened the statements demagogues, and not only dema- gogues that are making these state- ments, but men high the executive branches our greatest institutions learning, well-known figures the church, and leaders many other American groups are charges either major minor degree. What the truth? Well, genuine miracle has happened. The dema- text, suitable for use bulletin boards, will supplied Service Department. YOUNG President, Young Spring Wire Corp. gogues have been answered they have been definitely answered the most reliable and authentic source ex- isting the world today. Their wild inflammatory stories are proven false the Government the United States, and could not ask for much more dependable source in- formation than that. quite true that two years ago demagogue could make most any kind wild charge regarding the distribution our national income, and get away with it, just any one could say that the canals Mars were 200 ft. fo) ° ° our entire American manufacturing industry being operated for the benefit investors, own- ers, inventors, etc. THE IRON AGE, April hens atory pader = And who could disprove ment? And was much the same with the charges made demagogues the week the United States Gov- ernment released book that rapidly becoming nationally famous, namely, “NATIONAL INCOME THE UNITED is- sued the Department Commerce. This book was bombshell, but few people saw it. The book has been pub- lished for months, and only recently that business men have heard about it, yet they should more vitally interested its contents than any other book publication ex- cept the Bible. The Kiwanis Club Detroit was addressed Sherman Rogers, early August last year. was ex- cited group business that boiled out that meeting after was over. Mr. Rogers had been speak- ing throughout the Middle West be- fore business groups, giving out the amazing facts contained this ernment research report and calling attention its existence. had the good fortune hear that speech, and sat like 300 other business men did —literally spell-bound. had never heard the had never heard the figures. what the speaker said was true, per cent all the wild charges made from soap boxes and the thousands inflammatory pamphlets that have been written were fairy tales. When the address was over every man that room started looking for the book. Few them were able obtain one, but those that did soon passed the word those that didn’t. Here the basic fact, brought out this Government report. all the income produced and paid out the manufacturers the United States 1929, the employees received average cents every such dollar, and every such dollar income produced and paid out the manufacturing industry 1934 the employees received cents each dollar. Investigation proves that the same ratio holds good 1935, 1936 and 1937. Now first blush these figures may not seem important the average executive who has had least vague idea regarding the truth this statement for good many years, but the value this report lies the fact that issued not the manufacturers, who might charged with bias and propaganda and with hiding certain figures that might alter the full truth, but was issued thoroughly non-partisan group ex- perts who were position seek and find the truth. The Government 32—THE IRON AGE, April 1938 INE-TENTHS, least, the discontent and un- rest this country based upon lack information re- garding the actual distribu- tion our national income. Through this lack factual data, political demagogues, communists and professional "world have been able mislead the masses for their personal benefit and aggrandizement. Thus the fomentation envy and class hatred between the so- called and the "have nots" which has been characteristic the past several years. this article, the author kicks the soap box from under these demagogues means recent survey authorized President Roosevelt, conducted Secretary Commerce Roper, and published the Government Printing Office. This survey reveals the astonishing fact that employees receive cents out each dollar national income generated the manufacturing industries the United States. has access records that one else has access to. Now, let’s see what these figures mean the average man. They mean the difference between zealous Bolshevik and sound, loyal American, because when all said and done extreme radicalism and class hatred are, the main, caused economic little investi- gation will prove this point, and you can make that investigation any main street your own town half hour. When this booklet was published survey was made Chicago, where 518 men were interviewed coming out factory gates. Each person was asked how much each income dol- lar produced the manufacturer thought found its way into the pay envelopes the workers. The results that little investigation were aston- ishing, and tell amazing story. Well, here the answer: Out the 518 persons, 135 thought they got less than 3c. each dollar income pro- duced their industry, 378, including the 135, were the firm conviction that they got less than 5c. out each dollar, and only the entire 518 thought they got much 10c. each dollar income produced. Now, let’s analyze misleading beliefs. what these men believed true regarding what they received from the dollar in- come produced the manufacturer was actually true, they would certainly have been cowards they were any- thing else but extreme radicals. the system private enterprise, and our democratic form government fathered and fostered such unbal- anced and untenable distribution income produced, would high time change the system private enterprise and the government that fostered such outlaw system once. this case, what should do— throw bricks these people who were sincere their belief, should all community leaders shoulder the responsibility placing the facts before them? When you have an- swered that question the only way possible, you have pointed out the real reason for most the hatred that exists against our economic sys- tem, the underlying reason for much unrest among the average people this country. Here was group honest men, hard-working men and women, more than one-quarter whom believed that they received only one-thirtieth the share income they actually did receive they worked in. any wonder that confusion existed the minds these men? Two-thirds them be- lieved that they received about one- fifteenth what they actually did receive. Well, the difference between what these men actually received, and what they thought they received is, let repeat, the difference between loyal, constructive, sound-thinking American and extreme radical, eager for any and all changes. Any fair-minded reader will agree that. will bring any responsible business man with jerk will just out the street, and find the almost total lack understanding the average citizen regarding the dis- tribution our national income, and yet the most vital concern every man, woman and child this country that they know these facts. And most certainly prime im- portance every investor-business man and manufacturer. have been business man engaged the manufacture steel products for great many years. started with small crew. Today the plants | | q 7 J 7 and ment nbal- high ivate that do— were ulder facts an- way the atred so and only the stries that one- did tween and is, tween that. the ing dis- and ern this facts. im- isiness igaged rted plants bearing name are situated several parts the United States and Canada. have always imagined was good business man. When heard this speaker before the Kiwanis Club suddenly realized that during all these years business man, had ignored full responsibility the people working for me, their families, and all the people the communities where factories are located. Had spent just little time, could have made possible for all these people have been com- pletely familiar with the real facts concerning the distribution each dollar that our company took in, and there not the slightest question mind had done so, would have performed service tremen- dous value not only our company, but the community and nation. The speaker the Kiwanis meet- ing made another statement that has flitted back and forth mind ever since. any largé number people wrong leader, not because the wrong leader smart, due solely the fact that the right leader asleep the the more turn that statement over mind, admit the truth. There has been far too much re- crimination—most have acted very much like group excitable school children. have talked about formulas—we have talked about pan- aceas, and yet, when have looked them all over, know there only one solution any problem, and that the truth—the plain, basic truth, vigorously but tolerantly told. Certainly business men have made mistakes—labor leaders have made mistakes—political leaders have made mistakes—farmers have takes—and probably one group has made more than the other. Ninety per cent these mistakes have been sincerely made, and why should waste valuable time criticizing them now? firm belief that the time criticize past; the time solve problems facing them here. This Government survey thor- ough one—it goes into all branches the trade—all branches that make the life great nation. deals with agriculture, and points out how many dollars were taken in—how many dollars were paid out—and who received those dollars. does the same with manufacturers, with mining and quarrying, with electric light and power, with transportation, with con- struction, with finance, with com- YOUNG President, Young Spring Wire Corp. munication, with trade—both retail and wholesale, with government, and with service—thoroughly covering all branches where people are gainfully employed. mining and quarrying, for in- stance, the employee received 84c. each dollar, and the bankers, the stock- holders, the bondholders, and the in- corporated and unincorporated owners received the balance. Now, come service are all interested in, the wholesaler and the retailer. all the income pro- duced the retail trade, the stockholders and bondhold- ers, and incorporated owners and the bankers for interest, received only 4c. each dollar such income pro- duced and paid out, and since 1929 both wholesalers and retailers have paid out more than they have taken in, and have been calling their surplus for several years make the deficit. take look the rest the picture. The employees receive their pay envelopes 72c. each dol- lar income produced the retail and wholesale trade, and then come the entrepreneur—that word for you. doesn’t mean what you think does. means un- incorporated owner; and the retail trade means 1,432,000 little shop owners too small afford the ex- pense You will find these entrepreneurs little stores and small shops every city, village and hamlet throughout the country. You will find, rule, husband and wife —sometimes son and daughter will the sole help within the establish- ment. The Government its survey says this: “As the assumption was made that entrepreneurial withdrawals retail trade equaled the average full-time wage, these may considered largely the nature labor income. Combined with compensation em- ployees this branch trade, they constitute from per cent total income paid out.” Now, think over those figures moment, and they will most us. Any time that labor in- come amounts per cent the total income any great in- dustry, have distribution income more fair and more just than exists any other country What this remarkable Government research has done this—it has firmly established the wisdom and the sound- ness George Washington and his compatriots the Constitutional Con- vention, and has about completely demolished the visionary theories Karl Marx far the United States concerned, but these facts good boxed the printing depart- ment Washington. This book will settle more arguments regarding the American economic system than all the books now cluttering libra- ries, and for once can compliment the Government unstintingly real accomplishment. This book written language that any grammar school child can understand. get the truth contained this book into the hands and minds the people the United States, the intense animosity that has dethroned reason, and the scales prejudice that have blinded the eyes millions will largely dis- appear, and will all able sit down across table associates the building great enterprises, work out our problems basis mutual respect, and doing gain the co- (CONTINUED PAGE 83) THE IRON AGE, April 1938—33 518 king men what in- any- will 3 — » | 4 + ingots the plant Co. Photo Richie. men have ever heard the “Barbeque” method melting metal, the writer has Nonetheless, all foundrymen are quite tamiliar with the process most universal practice among and aluminum furnace tenders. tol lows the lines least resistance, and brass while may save few minutes bringing down melt, this practice very bad and most closely related annoying casting failures, often without the even suspect ing the reason. brought merely placing part the metal charge (ingots, gates, sprues and misrun the lid the furnace that the metal extends partly all the way across through the opening the lid, order pre-heat and melt this part the furnace charge and save time. When the true facts are known, how- ever, this most expensive and dangerous way “save” time. The idea pre-heating part the furnace charge reasonable, but the method employed definitely wrong Never should the metal charge come direct contact with the furnace for any period time beyond Ma (The fallacy melting, and other common practices which inevitably lead defective castings. FRITSCHLE Smelting Refining Co. seconds; for when metal lowed “soak” directly the fire hecomes badly harmful gases, and the chemical actions ruin the mix. Heat expands this metal before reaches the fusing point opens the pores, which permits com- metal. When these gases (hydrogen. oxygen and carbon monoxide), which are the products combustion within the furnace, are absorbed the solid metal, chemical reactions take place. when fusion occurs short thereafter, these gases become dis solved the molten mass. means this the only trouble producing condition created particular melting procedure. stance, the metal gradually reaches its fusion point and melting pro gresses, innumerable small drops molten metal out the still more less solid mass. Most these liquid drops metal, perhaps, quickly find their way down into the molten mass the crucible below, but great many these molten globules remain stationary just long right where they are formed—to be- come enveloped thin film oxide. This oxide film immediately retards the flow these globules and fur- ther their descent into the crucible below. the meantime, the oxide film becomes heavier and more pronounced and the globules become less fluid they continue ex- posed the furnace flame. The cycle continues until finally this oxidized (as the foundryman calls it) metal, drops down into the cruct- ble below where the are duced right into the rest the molten metal charge. Obviously, therefore, this faulty melting practice one stroke introduces both oxides and solved gases directly into the molten brass aluminum, which the foun- dryman expects pour into good sound castings Some the dissolved gases come out solution, were, but they not really get the castings; the evidence generally found right der the skin all the way through the structure when the castings are really remove dissolved gases requires remelting operation boiling, special treatment with considerable zinc (about per cent) and phosphor-copper (about per cent) which might conceivably alter the composition beyond allowed lim its and also result the molten cutting into the sand and core. perfectly feasible pre-heat castings, gates, sprues, etc., for later THE IRON AGE, April 1938—35 pe “ ° ° | | a = ° ° ; ‘ 7 | > at: = 3 introduction the initial charge melts down, thus maintaining melting schedules, without allowing this part the charge the fire. Simply place them top the fur- nace far enough away from the open- ing the lid that the flame doesn’t touch the metal. They will found sufficiently hot when pre-heated this manner into solution very short order. Even under favorable operating conditions and close melting control the foundryman has plenty annoy- ing problems worry going out his way set the stage for more trouble. conceded fact that foundrymen cannot operate under the very close supervision and control that possible research laboratory. simply necessary have more flexibility action and “elbow room” operating foundry. For these and other reasons very good idea for the foundryman check closely his melting prac- tice and train his furnace tender how handle his metals during the entire melting. The fur- nace tender’s job very although, the author’s years contacting brass and aluminum foun- dries all through the Central-Western and Southern parts the Uniied States, has been found that great many cases this important fur- nace tending job delegated raw novice who was incidentally general “flunky” around the place. Safety Factor Advisable very good idea adopt some definite and dependable safety factor connection with melting practice, that whole heat and all the time, labor and overhead expense involved miss procedure costly under any conditions. line with the forego- ing the author would recommend that every heat red brass and tin-bronze deoxidized before tapping out any metal pulling the crucible from the furnace. Phosphor-copper the usual medium employed for this purpose the majority brass foundrymen. But this connection the author has found that many foundry foremen and furnace tenders operate upon the theory that oz. phosphor- copper added 100 Ib. brass would noticeably improve the quality, then the addition oz. per 100 would six times This theory, however, most certainly does not work out practice and should all means discarded. 36—THE IRON AGE, April 1938 The method introducing phos- phor-copper into molten metal quite important and considerable extent controls the results obtained from phosphorus additions. this con- nection the writer has time and again observed furnace tenders throw their phosphor-copper right top the slag, charcoal dross-covered molten metal, and then search about for suitable iron rod stir the metal and work the phosphor-copper. the meantime, while the furnace tender was endeavoring locate his elusive stirring rod, most the phosphorus content burned out, and the impor- tant beneficial effects were thus dissi- pated the vanishing point. the vast majority min- used, but every case should im- mediately plunged the bottom the molten metal the and then stirred around vigorously for small amount phosphor-copper will have decidedly more effect than much larger amount carelessly thrown top the slag-covered metal sur- face. more dependable method deoxidiz- ing, and especially effective when running pressure castings, first introduce small quantity zine oz. per 100 Ib. metal charge, according the alloy) the molten metal the furnace about min. before tapping out any metal pulling the crucible. The zinc, like the phosphor-copper, should not thrown the surface the slag charcoal covering the molten metal; should immediately plunged the bottom the molten metal and stirred around very vigor- ously for sec. Then about min. after introducing this small quantity zinc, the phosphor-copper should introduced line with the foregoing recommendation. Probably many foundrymen would interested knowing why zinc and phosphor-copper are recommended red brass and bronze, since both, in- dividually, are deoxidizers. The rea- son that the zinc serves not only first-rate deoxidizer, but the some- what larger volume zinc causes violent boiling action which material- assists the upward movement oxide particles, which tangled and are held suspension. Whenever molten metal deoxidized and suspended oxides are even par- tially removed, the metal’s fluidity naturally improved. The phosphor-copper addition, be- sides deoxidizing the melted alloy. greatly liquefies the molten mass for brief period. Obviously very thinly-liquid through the force gravity, more readily and more definitely free itself pended oxide particles. most cases there desire retain the phos- phorus element—merely the re- fining effects the phosphorus are desired. That’s why, for general prac- tice, the author recommends adding min. before pulling the crucible tapping metal from the furnace. phosphor-copper added immedi- ately before pouring the metal into the molds, the practice great number foundrymen, quite likely enough phosphorus gas will tained the metal stream porosity the castings. The foundry- man may also find definite tendency the metal cut into the sand and core, The author’s observations along these lines have indicated numerous instances where the furnace tender, order avoid phosphorus gas the metal, placed his phosphor-copper the bottom the crucible along with the first part his metal charge. Upon checking the results, has been found that the castings showed all the earmarks insufficient deoxidizing. method deoxidizing and introduc- ing somewhat smaller quantity phosphor-copper, after small zine addition, the results were very satis- factory. Deoxidizing yellow brass dif- ferent proposition. considerable excess already present. which produces oxides therefore, nothing accomplished trying deoxidize adding more zinc. known, aluminum some- sible for various good con-copper very excellent deoxi- dizer for yellow brass. doesn’t dis- color the skin the castings and, upon remelting the gates, sprues, does not make the metal dirty and drossy, does aluminum. The writer has found that the addi- metal, introduced into the molten mass greatly improves the soundness yel- low brass castings. This manganese- copper addition followed min. copper, hard beat. But for every- day practice oz. phospher- ] | | | | | { | | ' ngs ient the luc- able mis- Sili- dis- and, etc., and OZ. mass nese- min. yhor- copper per 100 metal very satisfactory deoxidizer for yellow brass under almost any conditions. And for gas cocks and valves, which must not permit the odor gas copper being used every day with fine success one large brass founder. closing, there one more point that, although only nected with melting practice, im- portant include this discussion, the use gates sprues when the molten brass too hot. general proposition there excuse for over-heating the brass, although certain cases where heavy castings are run immediately after pouring thin ones, necessary bring the brass out very much the “hot side.” the latter event simply allow the crucible hot metal stand little while after pouring the light castings, until has cooled sufficiently, and stir uniform distribution the heat the molten metal. The use “coolers” frequently re- sults faulty castings, the defects having the appearance cold-shuts. reasonable assume that since requires almost one hour (or longer) bring.a furnace charge certain required pouring tem- perature, hardly conceivable that gates sprues introduced “cool- can reach the same complete state fluidity the balance the molten metal the crucible; and this line reasoning correct, then rea- sonable assume that, perhaps, various times during the pour-off, two metal streams different tempera- tures pass simultaneously over the lip the ladle, thus producing some good castings and some defective ones, all out the same heat and the very same crucible. The best way overcome all this uncertainty simply watch melt- ing temperatures closely and the use “coolers” under any condi- tions. The author has frequently ob- served many cases where the “coolers” were thrown into crucible hot metal and the metal thereafter molten metal was stirred around for sec. after the “coolers” were added, but even the latter event quite possible that the gates and sprues were still floating around, par- tially dissolved, similar cube ice glass warm water which has just been stirred. Modernizing Malleable Foundry SCHOBECK President and General Manager, Jamestown Malleable Iron Corp., Jamestown, SURVEY production meth- ods and metallurgical processes conducted heretofore the plant the Jamestown Malleable Iron Corp. revealed that while its op- erations and methods were par with the majority plants the country, there still remained much desired from the standpoint the owner, the customer and the worker. The need for faster and more cient production was met the in- stallation modern mold conveyor built conjunction with modern sand handling and reclaiming unit, with which molders, with min- imum effort, are able produce more and better molds over given period. They are also enabled devote their entire time the molding operation the pouring done separate group. The continuous molding operation brought about the need for continu- ous metal, which was met duplex- ing system which iron with satis- factory chemical analysis melted the cupola, thence run into conven- tional air furnace, where super- heated and refined under close con- trol, and from which continuously conveyed the waiting molds. This system has removed much the toil from the workers and has most entirely eliminated the dust haz- ard, which everywhere becoming increasing concern foundry opera- tors. Since the second step—and quite important step the first one—in- volved the so-called annealing the original hard iron castings, consider- able thought was given the various methods accomplishing this part the process. The problem was ap- proached from metallurgical stand- point with the idea first producing high quality castings, and second satisfying the consumer’s plea quick delivery. was, therefore, deter- mined that since the original hard iron castings are essentially mixture iron and carbon, when accompanied the proper ratios silicon, man- ganese, sulphur and phosphorus, they would respond under careful tempera- ture control heat treatment amazingly short time. The problem, therefore, resolved itself into one carefully applied and carefully con- trolled heat, under conditions which there would other deterioration. detailed description this unit fol- lows. will observed that here again tremendous dust hazard has been eliminated where packing ma- terials any description are used. Previously, the had been using old type periodic furnaces, tak- ing around seven days’ time for an- nealing, loading and unloading. contrast with the old malleable an- nealing period, the Jamestown cvcle now hr. This cycle can di- vided into four distinct intervals follows: (1) nine hr. heat the work from room temperature the maxi- mum temperature 1750 deg. (2) ten hr. holding 1750 deg. during which primary graphitization THE IRON AGE, April 1938—37 re - = eat | ind ous the = takes place; (3) two hr. quick 1425 deg. F.; (4) ten hr. tor slow cooling through the critical range 1425 deg. 1300 deg. During the last interval secondary graphitization (the pearlite into temper water cooled provide quick cooling the castings facilitate handling. Rollers Trays loaded trays were pushed through the over rollers mounted the furnace. was found that some from charge end, showing loaded trays about ready enter the charging vestibule. the rollers wore and, being covered with work, could not spected easily. trouble developed, was necessary cool the furnace for repairs and until cooled, the extent the damage could not anticipated, making impos sible estimate how long nace would down. Certain rolls were punished than others, being the constant high temperature zone all times. the new Jamestown furnace, each tray equipped with its own rollers wheels, fastened its bot- tom. Tray and wheels through the furnace channel-type 38—THE IRON AGE, April 1938 tracks extend longitudinally through the entire unit. Inspection the roll- ers after each trip through the fur- nace easy, punishment upon them equalized, and repairs tated without the necessity cooling the furnace. Firing Equipment Internally fired tubular elements (radiant tubes) are used the heat- ing medium, The tubes are made heat corrosion resisting alloy, in. and in. diameter. These tubes are arranged both above and below the work throughout the entire length top the furnace. the furnace structure provide the proper heating and cooling rates. Each radiant tube provided with specially designed combination pre mix and diffusion type burner, that each tube can controlled inde- pendently. The special function this burner produce long radiant flame inside the tube, which radiates through the tube walls without pro- ducing the excessive temperature dif- ferential found necessary when using entirely premix gas and air for com- Each tube with exhauster the outlet end facil- itate control the flame These exhausters also create negative pres- sure inside each tube, thereby pre- venting any leakage the products combustion into the furnace cham- ber case tube failure leakage welded joint. The fast cooling zone, where the temperature dropped from 1750 equipped with special through which cooling air sucked eductors using air from the main blower. Atmosphere Gas the atmosphere gas blend neutralize the given off the castings with proper amount Atmosphere unit may seen atmosphere which will minimize scal- ing, carburization and decarburiza- atmosphere from two three parts one part CO,. Usually this analysis from per cent about five per cent This atmosphere gas produced controlled partial combustion. Gas chamber and the resultant products combustion refined and cooled rid the gas detrimental water vapor. Before being introduced into the furnace they are first reheated utilizing the heat generated their combustion. q ven on scal- riza- parts istion water into their HARGING end the new fur- nace Jamestown Malleable Corp., Jamestown, Y., showing the new type trays ready pushed into the vestibule. The furnace provided with vesti- bules having doors each end prevent air infiltration when charging and discharging. Dimensions and Capacity The total length the furnace tween the inner vestibule doors dis- charge end showing tray dumping me- chanism and return conveyor. Water cooled tubes dis- charge vestibule fi- nally cool the work dling. each end ft. Internal width wall wall ft. Total overall outside dimensions are ft. width ft. in. long. Total fuel consumption 3300 cu. 1050 B.t.u. gas per net ton work. Capacity the furnace 1250 net Ib. plus 500 trays, rollers, per hr. tons work per 24-hr. day. Three rows are provided for trays, each row holding trays, making total the entire furnace (CONTINUED PAGE 94) THE IRON AGE, April 1938—39 Foundrymen ° Griffin Hot Blast RUDESILL Wheel Co. basic principle the Grif- fin hot blast process utilize the combustible coming from the cupola. applying the Griffin process standard cupola used the ordinary manner, with upper wind box added below the charging door. Through this second wind box portion the gas com- bustion drawn from the cupola and passed into combustion chamber where the inflammable carbon monox- ide gas burned temperature 1700 deg. developing increased amount heat which passes through the tubes the pre-heater and through exhaust fan. The air for the cupola blast enters the pre-heater among the tubes, which are heated with the cupola gas, and passes the cupola through the ordinary wind box. There are five doors the various chambers the heater for the purpose observing the entire operation and for examining the combustion chamber and exhaust chamber. accessible for periodical examination, simplicity the design makes the maintenance this type unit minor consideration. The design the pre-heater has been greatly modi- fied since the first units were installed. The old units were somewhat difficult maintain and prevent leakage, while the newer units the operat- ing economy and efficiency have been increased, and the warpage and leak- age the heater have been entirely eliminated. accurate record shows that that have been op- erating for years the plants the Griffin Wheel Co. have been main- IRON AGE, April 1938 tained over this period cost only 1.60 per ton product made. During this time about 1,897,970 tons product were made and the average coke ratio, including the total bed coke, was 185 per ton metal melted. This ratio represents sav- ing coke per ton, and amounts 35c. per ton metal melted. One the outstanding improve- ments that come with the installation the Griffin hot blast process the uniform increase that obtained the metal temperature. With blast temperature 600 deg. F., the metal temperature varies proportion the coke used per ton metal 125 Ib. coke per ton, will produce metal temperature the spout 2650 deg. When higher metal tem- peratures are required the ratio na- turally decreased and temperatue 2800 deg. easily obtained with the maximum blast pressure for melting high tons per hr. only the metal always melted under the most ducing conditions. The result this operation quiet molten metal free from any evidence iron oxide other non-metallic inclusions. This type metal known have lower hardness for given chemical analy- sis. Its machinability greatly im- proved and will much less likely chill castings that have thin edges than metal melted with the conventional cold blast cupola. cor- responding increase the fluidity also obtained because the favorable melting conditions. The application the Griffin hot blast process date has been very wide. Installations are being used ex- tensively the cast iron industry, both for miscellaneous types gray iron and for automobile castings. be- ing used the malleable industry conjunction with the malleable iron rgue furnace duplex process. The latest installations are being made the steel industry make refined metal recently developed process. The Acipco Hot Blast Cupola COTLIN American Cast Pipe Co. cupolas our plant are op- erated meet time, temperature, quantity and quality though our operation continuous, the melting rate must quickly va- ried over wide range, and times the cupolas are required stand-by. The iron must hot under all melt- ing conditions and after shutdown necessary that the first ladle hot. meet these conditions, our old cold-blast cupolas required heavy coke burden and high blast pressure. our foundries increased capac- ity was evident that some means producing high melting temperatures with lower coke burden would have found. The idea passing through cast iron sections set the wall the cupola below the charging door and above the melting zone was conceived. Experiments were made determine the proper location and shape the iron sections, and out these .experiments the blast cupola was The first installation was made November, vertical section this cupola shown Fig. The wind from the blower enters the bustle pipe and passes through riser pipes into cast- ings. Those castings were made cast iron inches thick and spaced that the front part forms the abra- sion zone the cupola. One casting used for each tuyere. The wind passes out through the bottom into | ° ° | | 7 Ss. Problems distributor which runs around the cu- pola and serves equalize the air flowing through the castings. From the distributor the wind passes down through cast iron downcomers and into the cupola through the tuyeres, The connections between the tubes and the bustle pipes are tight with glands and high tempera- ture asbestos gaskets. The tubes are anchored the bottom, throwing all the expansion the return bends above. The return bends are ma- chined inside and the straight ends the tubes are provided with three cast iron seal rings, piston rings, making- wind-tight expansion joints. Each return bend suspended from bracket with horizontal pin through lug the top the cast- ing such manner that the bend may swung out. This very convenient construction and mainte- nance feature. U-tubes Replace Castings improve our cupola operation the idea replacing the heavy cast- ings with series U-tubes was de- veloped, and 1935, the first installa- tion this type hot-blast equip- ment was completed. The melting zone lined with re- fractory blocks the bottom the tubes. Standard in. bricks are used between the tubes and the shell. Above the tubes iron bricks are used for the lining, which, with hot-blast equipment, are not subjected such extreme temperature conditions they are with the old cold-blast cu- pola. The principal cause tube failure the heating and cooling cycles through which passes. The length the heat apparently has very little with the life the tube. From series heats, ranging from hr. each, has been found that the average life hot-blast tube ap- proximately 150 heats. foundry insistent demand for better iron lower cost has led the development various refinements cupola operation and design, notably mechanical charging and hot blast equipment. the recent Birming- ham cupola symposium, held under the joint auspices the Birmingham chap- ters the American Association and the American Society Mechanical Engineers, considerable information was presented this subject two day session attended over 600 foundrymen. Presented herewith are abstracts some the papers read the meeting. Space limitations make impossible publish all the excellent material Particularly does this apply the very interesting discussion anced blast equipment presented Roueche, Sr., McWane Cast Pipe Co. However, data very similar nature will found article written Mr. Roueche for THE IRON AGE and published the issue Dec. 1937. Operating cupola alternate days affords ample time for ordinary re- pairs and tube replacements. usu- ally make all the required repairs and replacement about hr. with crew four men. The heaviest section weighs only 400 and does not re- quire special handling equipment. This type cupola very flexible may operated through short shutdown periods and the melting rate varied over wide range without ap- preciable loss temperature. long heats with high blast pressure the tuyeres remain bright throughout the heat. They not clog nozzle caus- ing oxidation they with cold- blast under these conditions. Present cupolas are operated with iron coke ratio between charges old cold-blast cupolas for this service, This represents average sav- ing about per cent coke charge. Very good results were obtained with this type hot-blast. inch cupola equipped with eight cast iron sections and tuyeres, the iron coke ratio between charges was in- the average melting rate was increased per cent and the average blast pres- sure was reduced from oz. oz. Temperatures were maintained the proper point and even the temperature dips were kept the region good iron. ° ° Mechanical Cupola Charging Pipe Foundry Lynchburg Foundry Co. pipe foundry question pro- duces pit cast pipe ft. long diameter, large fittings and wide variety special shapes for use the chemical industry. The plant equipped with four cu- olas each in. diameter inside the shell, lined in. above the tuyeres and in. below. Each capable melting from tons per hr. When charging one cupola hand, two crews four men each were re- quired the iron yard load the 4000 cupola charges. Thirteen ad- ditional men were necessary handle actual cupola charging, tend the cupola, deliver the iron, etc. The complete mechanization the THE IRON AGE, April re, us, by. VV re. the ing vas ind the and ced ing ind partition each bucket which serves stiffener and there eye the upper part this partition into which the charging crane hook fast- ened while being raised and lowered Expansion from the ground level the cupola Seal charging door. The bottoms the charging buckets are made two Cast iron semi-circular pieces hinged tube Construc- middle, that across the diameter. from the crane cab. Cold air Making Charges bustle pipe, chanical charging equipment consists making three metal charges and three coke and limestone charges be- fore the cast starts. The metal and coke are not mixed but are loaded separate buckets. While these charges are being placed the cupola three other buckets are being filled the bustle pipe iron yard with the crane and magnet. When operating one cupola with the mechanical charging equipment, one iron yard crane operator loads all metal charges. motorman who op- erates the Plymouth locomotive and hook-up man who works the ground beneath the cupola. charging BELOW crane bring all the iron and coke IG. 3—Sketch charges the cupola. The charging shows the manner crane operator does all the charg- which the Acipco S| Castiron ing. cupola charging operation required charges into the When operating two cupolas simul- the installation iron yard crane taneously three additional, total and magnet for loading the cupola charges, Shepard electric charging crane complete with nine charging buckets special design, cutting hatchway ft. ft. the charg- ing floor, enlarging the charging door openings the cupolas, and other minor changes. Scrap and Pig Unloaded Magnet Along one side the gage track where incoming shipments pig and scrap iron are placed prior unloading into bins loading di- rectly into cupola charging buckets. The 5-ton Shepard-Niles yard crane has maximum charging capacity between and tons per Just outside the crane runway and the opposite side from the standard gage track are series overhead coke bins with capacity approximately 450,000 Ib. coke. in, track runs from the cupolas the coke bins and the iron yard. Two track scales provide accurate weighing all coke and metal charges. Hydraulic. The special cupola charging buckets diameter and in. deep