The Iron Age 1938-05-12: Vol 141 Iss 19

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metollurgical Editor Associate Editor~ JURASCHEK Consulting Rdito: Washington Editor Resident District Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany MEYER CHARLES POST Milwaukee San Francisco SANDERSON Asa ROUNTREB, JR. Toronto, Ontario Birmingham Newark, N. J St Louis TURNER Buffalo ll Owned and Published CHILTON COMPANY Publication Office and Chestnut and 56th Executive Offices Philadelphia, Pa. 239 West New York, MAY 12, 1938 OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIO C. STEVENS. Vice-President JOSEPH HILDRETH, Goodbye Secrecy, Good Riddance Reflecting Changing Costs Casting Contracts JOHN VAN DEVENTER The Age 1938 Foundry Equipment Survey JULIAN CHASE THOMAS KANE Pools 1937's Progress CARROLL BUZBY Sand Equipment Predominates Devices for Foundry. Disposing Welding Smoke Crane Building Plant. Automotive Industry Washington News BAUR, General Advertising Manager THE NEWS BRIEF DIX, Manager Reader Service Plant Expansion and Equipment Buying Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 a year. Single copy, cents. Cable ‘‘Tronage, N. Y.”’ New Industrial Literature ADVERTISING Just Between Two 143 B. crman, ton g., Chestnut 56th 4 - ottenstein, 8 cago ‘ Leonard, 239 39th St., New York Index Advertisers Peirce Lewis, 7810 Woodward Ave., Detroit Box 81, Hertford, Conn. Copyright 1938 Chilton Company | | | | | : 3 | t | | | | i 3 | 4 | 4 | | | | | | | ac 29 J af 70 ; < 4 “Guide Treatment Shipped With the Steel Ryerson Certified Steels are not only shipped quickly, but complete information arrives with the bars, including chemical and physical properties and record heat treatment results. this way, the heat treater knows what each alloy and exactly how treat for the best possible results. This unique alloy plan, never before attempted any steel service company, the outstanding feature Ryerson Certified Steels. Ryerson Certified Carbon Steels, Tool Steels and Stainless Steels are ordered exacting specifications and pass rigid inspection before they are accepted for Ryerson stock. For high, uniform quality, specify Ryerson Certified Steels. They cost more and quick shipment assured. JOSEPH RYERSON SON, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. Alloy Steels—Tool Steels Heat Treated Alloy Steel Bars Stainless Steel Cold Finished Shafting Screw Stock Extra Wide Cold Finished Beams and Heavy Structurals Channels, Angles, Tees and Zees Hot Rolled Bars—Hoops and Bands Rails, Splices, Spikes, Bolts, Plates—Sheets Strip Steel, Flat Wire, etc. Boiler Tubes and Fittings Welding Rod—Mechanical Tubing Rivets, Bolts, Nuts, Washers, Reinforcing Bars Babbitt Metal and Solder fhe | DRILL MORE WORK TWIST DRILL AND MACHINE COMPANY NEW BEDFORD, MASS., U.S.A. NEW YORK STORE: 130 LAFAYETTE CHICAGO STORE: 570 WEST RANDOLPH ST. THE IRON AGE, May SPOUT MAGNETS Stearns Magnetic Mfg. Co., 635 So. 28th Milwau- kee, Wis. bulletin has been published featuring the large and junior types spout magnets which can furnished with automatic shut-off gates. FABRICATED PLATE WORK tion Engineering Co., Inc., 200 Madison Avenue, New York. Bulletin illustrates typical large fabricated products and pressure vessels, such bubble towers, autoclaves, digesters and tanks, which have been built the company. Shop views handling heavy plates and welding operations are included. HIGH SPEED STEELS—A Milne 741 Washington New York City. Bulletin describes various types high speed steels for cutting tools and points out recommended applications. delivered the company are accom- panied instructions for proper heat treating and each grade identified color applied the entire length the bar. MOLYBDENUM-TUNGSTEN STEELS Cleveland Twist Drill Co., East 49th St. Lakeside Ave., Cleveland, Booklet contains pages valuable information Mo-Max, denum-tungsten high speed steel. Physi- cal and chemical analyses are given and list licensees are included. INDUSTRIAL CRANES Brownhoist Corp., Bay City, Mich. Numerous types diesel and gasoline powered cranes, with capacity ratings from tons, are described and illustrated this bulletin. Photographs show construction details cations are listed tabular form. SPEED NUTS—Tinnerman Stove Range Co., 2038 Fulton Road, Cleveland, Bulletin describes the Speed Nut system fastening metal parts which said have affected considerable reductions assembly costs many instances where has been used. Typical ap- plications are illustrated and new method applying Speed Nuts in- accessible places described. TURRET PUNCH PRESSES—Wiedemann Machine Co., 1801 Sedgley Avenue, Philadelphia. Turret presses developed handle short run and low produc- tion work fast, efficient manner, are illustrated this bulletin. said that precision alinement any one punches and dies can had within seconds. Specifica- tions covering typical machines are given. PORTABLE WELDING EQUIPMENT Progressive Welder Co., 737 Piquette Avenue, Detroit. Portable hydraulic welding guns are pictured and de- scribed this folder. Line drawings show the many types guns that are available, while photographs are used show the guns action typical jobs. EQUIPMENT Aldrich Pump Co., Pine Street, Allentown, Pa. 20-page data book containing numerous hydraulic tables neering information. Included the tables are those pertaining ma- terials for pumping various liquids, diagrams discharge flow recipro- cating pumps and volume and capacity equivalents. BAR AND TUBE STRAIGHTENING Medart Co., 3500 Kalb Street, St. Louis. Booklet covers bar and tube straightening, polishing and sizing. Text describes the opera- tion the machines and photographs illustrate construction details. densed table specifications completes the publication. INSULATED General Electric Co., River Road, Schenectady. Much sulated cable are contained this 32-page booklet mation the types available, their construction, characteristics and appli- cations supplied. Simplified data how select the required conductor size are also included. BUILDING PRESSES—E. Bliss 53rd Second Ave., Brooklyn, attractive, profusely booklet covering the various manufac- turing units that make the com- pany. Many types presses are shown and there included brief discussion the manner which these machines affect contemporary social nomic conditions. SAND PREPARATION National Engi- neering 549 West Washington Boulevard, Chicago. The nine sizes Simpson intensive sand mixers and complete auxiliary equipment for cient molding sand reclamation, con- ditioning and handling are covered detail this 48-page booklet. Con- siderable space devoted discus- sion the fundamentals sand con ditioning. IDEAS ZINC—New Jersey Zinc 160 Front Street, New York. The cur- rent issue “The Alloy Pot” con- taining many suggestions for reducing costs the use alloys. interesting article this issue discusses new idea fastening die cast parts and comments handwheel design. FLAT WIRE—John Roebling’s Sons Co., 612 So. Broad St., Trenton, Catalog provides details concerning the characteristics cold rolled flat wire and describes the methods and equip- ment employed producing this prod- uct meet the exacting requirements. RAPID PRODUCTION LATHES —R. LeBlond Machine Tool Co., Madison Edwards Rds., Cincinnati. dissertation methods increasing production the use modern lathes. Examples where the use these mod- ern rapid production lathes doubled production are cited. STAINLESS STEEL Steel Corp., 436—7th Ave., Pittsburgh, Pa. This booklet veritable mine information the fabrication stainless steel. Welding acetylene, metal arc, atomic flash, fusion, covered great detail, and several pages the publication are employed illustrate joint design and welding technique. Soldering, rivet- ing, brazing and forming are also dis- cussed. CHROME STEEL TUBING AND BARS— SKF Steels, Inc., 369 Lexingtno Ave- nue, New York. Catalog lists 200 sizes seamless chrome steel tubing sizes ranging from in. 10% in., and sizes bars ranging from 0.335 in. in. diameter. Analyses, heat treat- ment recommendations hardness diagrams are given. LAPPING COMPOUNDS National Broach Machine Co., St. Jean Shoemaker St., Detroit, Mich. Red Wing lapping compounds, available eight different grades, are described this folder. Compounds are designed promote rapid precision lapping low cost. POWER Machine Tool Works, 637 Northland Avenue, Buffalo. describes power squaring shears capacities in. which were recently added the company’s line. Construction de- tails and dimensions are listed. i 4 NY | | | IRON AGE, May 12, 1938 SCREW PUMPS—Quimby Pump Co., 340 Thomas Street, Newark, Three bulletins are available describing the construction and operation various and sizes screw pumps for handling liquids and semi-liquids. Sim- plicity construction said provide unusually long life and low mainte- nance Costs. Wheel Co., 1344 Altgeld Chicago, Ill. folder describing the Cullman Drive, electric motor unit designed especially for driving machine tools. Unit provides belt drive smooth- ness and eliminates the need coun- tershafts and overhead belting. List prices various types are given. WELDING EQUIPMENT Progressive MATERIAL HANDLING—Wellman Engi- neering Co., 7000 Central Ave., Cleve- land. This useful catalog comprised series individual bulletins, each describing type bucket manufac- tured the company. Williams power- arm type, multiple rope, clean-up, dredging, hook-on and dragline types and specially built buckets mill and miscellaneous service are few the types described. FORGING PRESSES Ajax Mfg. Co., Chardon Road, Euclid O., Cleveland. Solid frame forging presses equipped with patented direct-acting air clutch are described bulletin No. 75. great detail. -stated that hot and cold coining stampings and forgings the use these machines eliminates milling, facing machining operations. BAKELITE PLASTICS—Bakelite Corp., Park New York. The story bakelite plastics, from the time their discovery the present day, told concise, entertaining this new booklet. Various types bakelite plastics and their applications are also discussed. WELDING ELECTRODES Page Steel Wire division, American Chain Cable Co., Inc., Monessen, Pa. new electrode called Page Hi-Tensile the shielded arc type, suitable for use with either motor generator transformer type machines, described this booklet. electrode es- pecially recommended for flat and posi- tioned fillet and general flat welding. ROLL GRINDERS Farrel Birmingham Co., Inc., Ansonia, tions, weights, construction and opera- tion details, and floor plan Farrel heavy duty roll grinders are given this 28-page bulletin. Grinders are available six standard sizes from between centers. MACHINE TOOL DRIVES Cullman Welder Co., 737 Piquette St., Detroit, Mich. Booklet describes and illustrates portable hydraulic welding guns and other equipment. Suggestions for per- forming special welding jobs are given and photographs illustrate typical uses. CONTINUOUS PRODUCTION—Mathews Conveyor Co., Ellwood City, Pa. instructive pictorial presentation the company’s entire line conveying equipment, including the recently de- veloped spring The application this equipment various industries illustrated nu- merous photographs and the principles governing the choice this equipment discussed detail. FLEXIBLE METAL HOSE American Metal Hose division, American Brass Co., Waterbury, Conn. describes flexible metal hose and tubing that described “the safest connec- tor between two moving parts.” Use the hose for carrying air, oil, water, steam and fuels various kinds, under all conditions, are illustrated. Engi- neering data capacities and work- ing pressures are given. ELECTRO-GALVANIZING—The Meaker Co., 1615 So. 55th Ave. (Cicero Sta- tion), Chicago. 30-page handbook containing much practical information galvanizing equipment and methods. particular interest the newest for this literature mention ADJUSTABLE methods galvanizing wire which described detail this publication. BUILDING MAINTENANCE Skybryte Co., 3123 Perkins Ave., Cleveland. This catalog devoted providing answers problems industrial engineers con- cerning the maintenance metal, con- crete, wood, glass and composition surfaces. unusual feature the catalog color chart which shows the various colors available Skyco paints. CHROME NICKEL MOLYBDENUM Sons Co., 211 Southport Ave., Chicago. 104-page processes working various types alloy steel forgings. Technical data, in- cluding specifications, chemical compo- sitions, tables weights for all shapes bars, and table die block weights are included. PORTABLE ELECTRIC TOOLS Skilsaw Inc., 3310 Elston Ave., Chicago. Illus- trated catalog portable saws, drills, belt sanders, disc sanders, grinders and blowers. Features are pointed out closeup photographs, and specifications and list prices are given. REAMERS Wetmore Reamer Co., 418 No. 27th St., Milwau- kee. Reamers, boring bars, units for bars, boring and turning heads, and specia! tools are illustrated and de- scribed this new bulletin. DIE CUSHION—Dayton Rogers Mfg. Co., 2830 13th Ave., South Minneapolis. 30-page catalog universal pneumatic die cushions. Profusely illustrated with diagrams, photographs and diagram- matic drawings. Specifications and technical data included. ARBORS—Scully-Jones Co., 1901 So. Rockwell St., Chicago. 16-page bulletin containing illustrations and complete specifications various types mill- ing machine arbors. Prices are included. HYDRAULIC PUMPS—Racine Tool and Machine Co., 1755 State St., Racine, Wis. Variable volume pumps the radial vane type are discussed and il- lustrated this bulletin. PRECISION GRINDER Boyar-Schultz Corp., 2110-24 Walnut St., Chicago. Profile grinder for precision work pictured and explained’ which also contains list specifica- tions. THE IRON AGE, May j | x Ne y o Car Receiving Receiving Storage Storage Process Through Process Process into Storage Storage Packing Packing into Car details moving loads from Receiving Raw Storage may seem drab and un-showy, but they not conceal the fact that right here place where some your most important savings profits—in materials-handling can created. Elwell-Parker has exactly the right equipment for this particular service. this case, especially-built power-dumped body forms the best container. other instances, Trucks similar type are designed handle large unit-loads platform, while smaller units are transported multiples skid boxes. The system flexible and can devised suit your types load and plant conditions. How you can profit applying Elwell-Parkers not only your “Step No. but other kinds plant materials-handling jobs well, will ably demonstrated experienced Elwell-Parker Representative. will co-operate with your Staff analyzing your methods and will explain the Elwell-Parker System Load-Transportation: Trucks correct type, with attachments most suitable for the specific job, together with carefully-developed Operating Plan. The Elwell-Parker Electric Com- pany, 4225 St. Clair Avenue, Cleveland, Ohio. ESTA RECEIVING * 4 i ESTABLISHED 1893 BUILDING POWER INDUSTRIAL TRUCKS SINCE 1906 IRON AGE, May 12, 1938 7 Q THE IRON AGE ... MAY 12, 1938 ESTABLISHED 1855 Vol. 141, No. Good-Bye Secrecy, Good Riddance RON founding was esoteric pursuit years ago, with every cross-road melter smugly applying individual guesswork within the confines his melting and moiding floors. Casting characteristics were most uncertain, tensile strengths were hardly 20,000 per sq. in., sand control was college stuff, and chemical control was altogether too new fangled when everyone knew that fracture tests were good enough for Father and Grandfather. The inevitable result was static industry, progressively harried technically the demands design engineers, ruinous competitive sorties fabricat- steel, welded steel, forgings and die castings, and hamstrung economically reckless bidding based ignorance proper cost systems. Then out the college came Turner, with his determination the effect elements, especially silicon, cast iron, and Howe, with his micrographs and an- noyingly persistent emphasis carbon control; along came the manufacturer metals, coke and fluxes with his technical research and metallurgist-salesman, and even the foundryman bestirred himself and figured out better cupola control, more flexible casting design and analyses and rapid and accurate molding techniaue. But, major importance during this period was the leadership and emphasis technical cooperation the American Foundrymen's Association. Then, all that was needed was sharp fillip from War demands give the casting industry its renaissance, albeit halting renaissance but none the less persistently accelerating. And today, the casting consumer accepts tensile strengths over per sq. in. and tolerances low 0.006 in. his due, and acknowledges unique damping characteristics, and wear, corrosion and impact resistance, and ability take multitude metallic, mineral and synthetic types surface finishes. maintain and addition enhance this position, the foundry industry this week Cleveland assembles for the forty-second time for cooperative attack all-important commercial problems such more uniform cost finding practice and more intelligent market research. And particular value will reports technical investigations along many fronts, fronts that could well include greater attention bi-metallic castings, reduction the quantities special elements essential bestow demanded physical properties, and better correlation variables cupola operation. te . a ® : | i 7 Ab : HYMAN BORNSTEIN behind for week the familiar sounds hissing air lines, chattering chipping ham- mers and thumping bumpers, foundry- men from all sections the country will meet Cleveland, May for the 42nd annual coavention the American Foundrymen’s Associa- tion, The program for the convention calls for sessions, with papers and committee reports branches the industry, arranged that sessions dealing with each branch the industry will held two consecutive days. Gray iron and non- ferrous meetings will held Mon- day and Tuesday, steel sessions Tuesday aad Wednesday and malle- able Wednesday and Thursday, while the management and general in- sessions will distributed throughout the four days technical meetings. Following the precedent set the 1937 convention, the year has been organized provide meetings interest foundry ex- 36—THE IRON AGE, May 1938 ecutives. Meetings listed under this heading include melting, cost methods, foreman and apprentice training, safe- and hygiene, and job The equipment and supplies exhibi- tion that held conjunction with the convention will open Saturday, Foundrymen onvene eveland for onvention while the technical meetings will not until the following Monday. The equipment and supplies exhibition will provide the foundrymen attending the convention with excellent oppor- tunity see and study the latest de- velopments this field. Program the 42nd Annual Convention A.M. OPENING MEETING Presiding, President Bornstein. Address Welcome. Announcements. A.M. 10:00-12:00 GRAY IRON Chairman, Dr. James MacKen- zie, American Cast Iron Pipe Co., Birmingham. Vice-Chairman, Weston, Chicago Hardware Co., North Chicago, 10:00 Hints Molding and Prepara- tion Castings for Corp., Cleveland. Enamelability Cast Iron, Dr. Spencer-Strong, Por- celain Enamel Mfg. Co., Balti- more, Committee Report presented Committee Chairman, Mahin, Westinghouse Electric Mfg. Co., East Pittsburgh, Pa. A.M. 10:00-12:00 NON-FERROUS FOUNDING Chairman, Harold Roast, Cana- dian Bronze Co., Montreal. Western Electric Co., Chicago. 10:00 Heat Treating Zine Bronze Pres- sure Castings Close Leak- Bunch, Pearl Navy Yard, Hononlulu, 10:40 Risers and Gates for Non-Ferrous and Brisbois, Robert Mit- chell Co., Ltd., Montreal. 11:20 Modification the Saeger Fluid- ity Test Applied Red P 4 ‘a = % “> =~’ A Brass, George Halliwell, Kramer Co., Chicago. 11:40 Annual Non-Ferrous Division Business Meeting. Presiding. John. Report Committee Analysis Defects. Report Committee Recom- mended Practice. Election Officers. P.M. 12:30 Joint Committee Foundry Re- YMAN BORNSTEIN fractories—Luncheon. left) P.M. 12:30- 4:30 CHAPTER CONFERENCE research, Deere LUNCHEON MEETING Co., will relinquish the Presiding, Vice-President Marshall presidency the Amer- Post. ican Foundrymen's Asso- P.M. 2:00- 4:00 FOREMAN TRAINING Presiding, Lynch, Case (right), vice-president, Racine. Wis. Birdsboro Steel Foundry Address Horrocks, Edu- Machine Co. Mr. Post Director, National Asso- served director ciation Foremen, and Good- the association during year Tire Rubber Co., the past three years and Ohio. keeping with tradi- P.M. 2:00- 4:00 PATTERN MAKING tion, Mr. Chairman, Vaughan Reid, City direct Vice-Chairman, Harrold. tion for three-year Caterpillar Tractor Co., Peoria. term beginning with the coming fiscal year. 2:00 Modern Pattern Production, Kindt, Cleveland. 2:40 Pattern Developments and Mold- ing Methods, Edward Hy- nans, Saginaw Malleable Iron Division, General Motors Saginaw, Mich. :20 Pattern Making Apprenticeship Caterpillar Tractor Co., Ill. P.M. 2:00- 4:00 GRAY IRON Chairman, Fred Walls, Interna- tional Nickel Co., Detroit. MARSHALL POS Vice-Chairman, Garnett Phillips. International Tractor Works, Chicago. 2:00 Physical Properties Cast Iron Young, Crosby, and International Nickel 8:00 Job Evaluation for the Smaller Herzig, Climax-Molybdenum Bayonne, Foundry, Roth, Motor Detroit. How Can Foundry Course Casting Co., Milwaukee. 2:40 Some Effects Blast Pressure Engineering School Demonstration the Use the Cupola Operations, Highest Requirements En- Occupational Rating Plan the Donoho and Dr. James Mac- gineering Course, Carl Industrial Management Society, Kenzie, American Iron Casberg, University Presented Ralph Landes, Pipe Co., Birmingham. Urbana, Western Electric Co., Chicago, 3:20 Charactertistics and Director Study and Re- Cupolas review paper P.M. FOUNDRY REFRACTORIES originally presented before the Chairman, Bowers, Ameri- Society. Institute British Foundrymen Cast Iron Pipe Co., Bir- Paper reviewed and Vice-Chairman, Elmer Carmody, abstracted Ada, Mich. A.M. SAND SHOP PRACTICE American Cast Iron Pipe Co. 8:00 Effects Cupola Practice Birmingham. Linings, Donoho, Chairman, Frank 3:50 Cupola Practice—by Marcel Du- American Cast Iron Pipe Co., Walworth Co., Boston. douet, Ecole Superieure Fon- Birmingham, and Practical Problems Non-Ferrous derie Paris, Greene, Atlantic Refractories Sand Control, Discussion Leader, Exchange paper presented be- Co., Macon, Ga. Arbogast, Northern Indi- half the French Foundry Characteristics the Silica Re- ana Brass Co., Elkhart, Ind. Technical Association. fractories Used the Cupola, Head Refrac- A.M. 10:00-12:00 NON-FERROUS CASTINGS P.M. 4:00- 5:30 CAST IRON SHOP PRAC- tories Dept., University Shef- Chairman, St. John, De- TICE COURSE—SESSION field, Sheffield, England troit Co., Detroit. Chairman, Horace Deane, Deere Exchange paper presented Vice-Chairman, Dr. Dayton, Co., Moline, behalf the Institute British Battelle Institute, Co- Cupola Operation, Donald Foundrymen). lumbus, Ohio. Reese, International 9:20 Refractories for Foundry Ladles, 10:00 The Role Silicon Non-Fer- Inc., Bayonne, Bales, Ironton Fire rous Castings, Dr. Brick Co., Ironton, Ohio. Gillett, Battelle Memorial In- P.M. 6:30 ENGINEERING AND SHOP stitute, Columbus, Ohio. PRACTICE P.M. JOB EVALUATION 10:40 Description the Age Harden- DINNER Chairman, Robson, Contin- ing Process Applied Cast- Chairman, Frank Steinebach, ental Roll Steel Foundry ings, Kempf, Research The Foundry, Cleveland. East Chicago, Ind. Laboratories, Aluminum Co. Discussions Vice-Chairman, Wartgow. America, Cleveland. What Course Metallurgy American Foundries, East 11:20 Production Castings Age Should Teach, Fred Sefing. Chicago, Ind. Hardenable Nickel-Tin Bronzes, THE IRON AGE, May 1938—37 7 Se | Ay j technical sessions the con- vention and the foundry equip- ment exhibition will held the spacious Cleveland Public Audi- Nickel Co., Bayonne, N. J. A.M. 10:00-12:00 STEEL SESSION Chairman, John Howe Hall, Ger- mantown, Philadelphia, Pa. Vice-Chairman, Hartman, Bethlehem Steel Co., Bethlehem, Pa. :00 Report of Committee on Radiog- raphy, Presented by Committee Research Laboratory, Washing- ton. 11:00 Effects Aluminum The Physical Properties of Medium Carbon Cast Steel, by C. E. Sims and Dahle, Battelle Memorial Institute, Columbus, Ohio. 1¢ A.M. 10:00-12:00 GRAY IRON Chairman, John Bolton, Lunk- enheimer Co., Cincinnati. Vice-Chairman, Max Kuniansky. Lynchburg Foundry Co., Lynch- burg. Va. :00 Deoxidation and Graphitization, America, Detroit. :40 Comparative Effects of Late Addi- Silicon and Titanium Titanium Alloy Mfg. Co., Ni- agara Falls, 11:20 The Formation Battelle Memoria! Institute, Co- lumbus, Ohio. P.M. 12:30- 3:30 NON-FERROUS ROUND TABLE LUNCHEON ENCE Chairman, Rowe, Aluminum Co. America, Cleveland. Crucible Melting Furnace Develop- ments, Stone, Vesu- vius Crucible Co., Swissvale, Pa. Analysis Causes and Remedics for Certain Types of Defective Casting. P.M. 12:30- 3:30 GRAY ROUND TABLE LUNCHEON CONFER- ENCE Chairman, Kenneth Briggs, Western Foundry Co., Chicago. Vice-Chairman, Massari, Association of Chilled Car Whee! Manufacturers, Chicago. Discussion: Graphitization and In- Cast Iron. 38—THE IRON AGE, May 1938 P.M. 4:00 APPRENTICE TRAINING Chairman, Freund, Univer- sity of Detroit, Detroit. 2:00 Wisconsin Training Plan, by J. E. Tepoorten; Coordinator, Occupa- tional Extension Service, Wis- consin Vocational Schools, Madi- son. 2:40 Foundry Apprenticeship in a Commercial Shop, by E. N. Brough, Fairbanks, Morse Co., St. Johnsbury, Vt. 8:20 Canadian Apprentice Training Situation Western Canada, Foundry, Ltd., Winnipeg, Can. 4:00 FOUNDRY COST METH- Chairman, Sam Tour, Lucius Pit- kin, Inc., New York. Melting Costs Non-Ferrous——A. E. Grover, Beres. Ohio. Castings Co., Buffalo. Malleable—R. Belt, Malleable Founders’ Society, Cleveland, and Anderson, Belle City Malleable Co., Racine, Wis. Gray Rentschler and V. L. Diefenbacher, Hamil- ton Foundry Machine Co., Hamilton, and Grede and Lee, Liberty Foundry Co., Wauwatosa, Wis. P.M. 2:00- 4:00 STEEL CASTINGS Chairman, Everett, Key E. St. Louis, Tl. 2:00 Study Steel Molding Sands. and Schuch, Harry Dietert Co., Detroit. 3:00 Report Committee Producing Steel for Presented Committee Chair- man, Phillips, Dodge Stee! Co., Philadelphia. 3:30 Report Committee Heat Treatment Steel Castings. Presented Committee Chair- man, Zuege, Sivyer Stee! Casting Co., Milwaukee. P.M. 4:00- 5:30 CAST IRON SHOP COURSE —SESSION Chairman, Korte, Foundry Co., Detroit: Cupola Practice—Burnt Iron, Dis- cussion Leader, Dr. James MacKenzie, American Cast Iron Pipe Co., Birmingham. EVENING—STAG PARTY P.M. Atlas A.M. A.M. A.M. A.M. A.M. WEDNESDAY—May SAND SHOP COURSE— SESSION Chairman, Donald Yost, Budd Wheel Co., Detroit. Practical Problems Gray Iron Sand Control, Discussion Leader, Wilke, John Deere tor Co., Waterloo, Iowa. 9:00-11:00 APPRENTICE TRAINING DEMONSTRATION Demonstration Cleveland Trade School. 9:00-11:00 MALLEABLE CAST IRON Chairman, Dr. Schwartz, National Malleable Steel Castings Co., Cleveland. 9:00 Spheroidized Pearlitic Malleable Cast Iron, Duncan Forbes, Gunite Foundries Corp., Rock- ford, 9:40 Production Short Cycle Mallea- ble Iron, MeMillan, International Chicago. 11:20 Pearlitic Malleable, Ben- ninghoff, Ohio Crankshaft Co.. Cleveland. 9:00-11:00 STEEL CASTINGS Chairman, Melmoth, Detroit Steel Cesting Co., Detroit. 9:00 Report Committee Coupon Tests, presented Committee Chairman, Sampson, Gen- eral Electric Co., Schenectady, 9:20 The Effects Deoxidation Treat- ments the Ductility Cast Steels, Gagnebin, Inter- national Nickel Co., Bayonne, 10:00 Steel Casting Design for the En- gineer and the Foundryman, Naval Anacostia, Washington, and Gezelius, Taylor-Wharton Iron and Steel Co., High 9:00-11:00 SAND RESEARCH Chairman, Harrington, Hunt-Spiller Mfg. Co., Boston. Vice-Chairman, Harold John- son, Greenlee Foundry Co., Chi- cago. 9:00 Effects Different Electrolytes A.F.A. Clay Determinations, Haseman, Cornell Uni- versity, Ithaca, (CONTINUED PAGE 45) ar p q problem confronting the manager jobbing foundry considering the execution contracts covering the sale castings that protecting himself against unforeseen rises raw material costs, and the same time providing sim- ple, equitable method for adjusting costs downward the event de- cline material costs. One solution this problem avoid term contracts entirely. This method, however, presents the possi- bility undesirable fluctuations production levels from day day, and the purchaser without assur- ance permanent source cast- ings. Between these two evils, however, there practical solution this problem. The author has developed form casting contract which does reflect general changes foundry costs while protecting both parties the contract. not dependent upon cost system the foundry nor does require complicated calculations set up. The Contract Setup This contract predicated sim- ple, definite form market factor that reflects contemporary conditions the raw material markets and varies from the conventional contract only the manner which prices are set Reflecting Changing osts Casting Contracts ° ROBERT KLISE ° forth. other respects may take whatever form desired the con- tracting parties. may require- ments contract contract for definite number pieces. Deliveries may scheduled left reasonable diligence. the example which fol- lows, there are set portions actual contract price schedule moderate-sized foundry making light gray-iron machine parts. Table shown the contract price setup. With the exception the column headed “part constant,” this setup similar the conven- tional contract. The “posted piece column shows prices agreed upon and force the time the contract signed. These prices may modified any time the foun- dry within the limits the part con- stant applied. The part constant, may not changed during the life the con- tract except for weights, etc., and determines the maximum price which the foundry may charge for the casting. The method using these constants de- termine maximum piece prices for the various parts follows: For par- ticular casting under consideration, the maximum price per piece equal its part constant, set forth Table times the current market multiplier, determined from ° ° time time according the method shown Table II, times the weight the part, or, maximum piece price The term “market multiplier” the heart the whole contract, for this the factor that keeps the contract prices line with the raw material market. This multiplier lated from definite formula every time there price adjustment the raw material market. takes less than five minutes compute and does not require any knowledge foundry practice. Table shows how the market multiplier built up. Having determined market multiplier, the cost per piece figured the following manner, using casting example. The part constant for this 6.3069 and the multiplier determined Table 0.00724. Multiplying these together the result 0.045662. This the price per pound for the part ing this the unit weight the casting the result this piece price compared with the stated piece price Table seen that there difference 0.82c. these prices. This difference represents the allowable increase price per piece for this part under the contract. Nothing the contract states that this increase mandatory. What the THE IRON AGE, May 1938—39 3 i 3 7 3 | 4 TABLE Casting Posted Minimum Symbol Piece Price Pounds Part Constant Quantities A £02050 3.500 S.0224 50 Lb 2725 6.500 5.9158 50 E 1.3400 30.060 6.2690 10 Above schedule subject correction weights, correction for errors specifying pattern equipment furnished, and correction for changes patterns. Minimum are quantities per order, not including blanket orders. Posted piece price subject change within the limits the contract. contract does state that the foundry may, its option, and upon reason- able notice the purchaser, post increase the piece price this part not exceed this difference. Or, had this difference been negative, the foundry must notice from the pur chaser, reduce its price this part least the amount this differ- ence. other words, the price determined the method described above are maximum prices not practice, with this type advisable keep exceeded. contract, the posted piece prices slightly under the contract maximums order that frequent small changes the market multiplier will not necessitate gen- eral revision prices. Possible Variations variation this form con- tract which will frequently more satisfactory provide for the correction the posted prices definite intervals. Depending the sensitivity the items used make the multiplier, the interval might be, for example, one week, two weeks, one month. Another method using the prin- ciple the market multiplier eliminate entirely the posted piece prices. Instead these prices, let the contract provide for payment prices determined according the market multiplier the date de- livery. delivery daily nearly so, would seem better many cases provide that all parts delivered within definite period are paid for prices determined the market multiplier for definite day that period. Other advisable modifi- cations may appear One thing bear mind con- nection with the multiplier that the necessity for frequent calculation not great. Some material prices re- main unchanged for period time. easily possible 40—THE IRON AGE, May 1938 after little practice tell glance change market quotations influ- ence the contract prices any ex- tent. Choosing the Components The problem picking the items which are used determining the market multiplier one requiring careful consideration. most con- tracts with purchaser the same, practically the same, mix iron used for all the parts covered the contract. only necessary determine this mix and from select the principal items price the mix the spout. seldom advisable use all the items the mix because several TABLE The method determining market multiplier any given time shown below. The illustration based plant located the Detroit area. Take per cent quoted price No. foundry pig iron, f.o.b. Detroit. per cent quoted price Silvery pig iron, f.o.b. Jackson, Ohio. per cent quoted price No. machinery cast scrap, f.o.b. Chicago, mean price. per cent quoted price steel rails, two feet and under, f.o.b. Chicago, mean price. The total these figures represents the price for composite ton. The price for composite pound determined divid- ing this figure 2000. The the composite price per pound, the market multiplier. Below example this No. Foundry Iron.$18.50 .40 $7.40 No. Machinery Cast 9.25 4.16 2000 $14.48 Market Multiplier $0.00724 them will unimportant far price change concerned. exam- ple the use limestone for The price limestone might double triple, yet inexpensive enough that the few shovelsful used will have negligible cost the iron the each charge effect spout. will noticed that the price coke not included the example. The reasoning behind this omission that coke prices increase very much, pig iron will have ac- weight given the pig iron the mix and the coke factor eliminated. choosing items for use the market multiplier essential use materials for which there estab- lished market and frequently published used the average mix are listed weekly the market order set the various part constants only necessary figure each piece price price per pound whatever way the estimator ac- customed so. Then the current market multiplier calculated. When pound price used divide the multiplier and the result the part constant. piece price used divide both the piece weight multiplier get the part constant. desired have slight leeway, suggested, this should added the estimated price before making the calculation. Taking casting example assume that Table being made with market multiplier 0.00724. After adding slight leeway, the piece price determined The part constant therefore equal 12.25, which gives part constant the items and their percentages weight are chosen carefully with reference the actual mix, the mar- ket multiplier obtained any time will represent definite, essentially constant proportion the true cost the iron the spout. the above example the market multiplier was roughly pound. The cost the mix actually used might the neighborhood 1.4c. the spout. the items Table were proper- picked and weighted would ex- pect the true cost the spout rise very close two cents pound when the multiplier reaches one cent. The difference between the multiplier and the cost the spout represents all in — p 0 Is In | conversion labor and overhead well other materials not used com- puting the multiplier but which are contained the mix. These items automatically are taken care the part constants shown later. Labor Costs the price the finished casting there remains considered mold- ing overhead, cleaning expense, general overhead besides the molding labor and core expense. Each one these items can be, and frequently is, expressed percentage the molding labor labor and cost the spout. foundry that does mostly one class work, which reasonably de- partmentalized, such approximations, carefully made, not depart ma- terially from the true costs. For any particular casting, the molding labor cost the spout. The same true core expense. Hence, all these cost items, including labor, may expressed percentage the cost the iron the spout. therefore, that the selling price each part may represented percentage the cost the iron the spout. The selling price may also definite portion the cost the spout. The provision this contract for changing labor costs indirect but none the less definite. for example, material prices rise that there average increase per cent the cost the material used, the mar- ket multiplier will rise almost exactly per cent. The exactness this parallel trend will, course, depend the care, with which the items the multiplier were chosen. per cent rise the market multiplier, obvious, will provide for per cent increase the selling price. This increase the selling price turn allows for per cent increase the cost the labor involved mak- ing the parts. The converse true the market drops per cent. Other Cost Factors The analysis just set out for labor also holds true for overhead. There are, however, certain differences the usual overhead situation which should considered. What might called variable direct overhead will usu- ally increase rather close ratio with direct labor. That is, when you have pay labor per cent more you will also have pay supervisors and the service labor about per cent advantages gained employ- ing modern scientific instruments con- trol the quality the mixture are often lost times rapid fluctuations raw material prices casting contracts that are not con- structed these changes. ° ° ° more. Other items overhead which fall this category will readily called mind. There is, however, such exact relationship between rising material costs and what usually called fixed overhead. Interest investment, de- preciation, insurance and such items will rise much more gradually, all. consider the unused por- tion the allowable per cent in- profit, the results will not out line with current practice under the sale manufactured goods. The foregoing demonstrates that the market muitiplier provides ef- fective corrective for changes the manufacturing cost castings and reflects, when used with the part con- stant, the proper price correction cover changes this cost. not contended that this exact meth- od, but only that this method provides approximation sufficiently accurate for most practical purposes. not necessary rely entirely analysis the basis this contractual setup order justify the system. The sample calculation the market multiplier for the date May 1935. October 1937, the current market multiplier, Photo courtesy Ford Motor Co using the same factor, was 0.0097187 compared the earlier multiplier 0.00724. This represents increase about 34.5 per cent contract prices used the examples. For the same period practically identical group parts, not made under this type contract, figures are available showing that there has been actual increase prices charged amounting about per cent. These latter prices were quoted and accepted with- out any limiting contractual obliga- tion the part either party. should also considered that prices set from the usual cost estimates cannot expected reflect true does the market multiplier. This because the necessary lapse time required collect and compile cost data which may already incorrect the time they are ready for use. The closeness with which these two percentages match conclusive proof that the market multiplier type con- tract sound when set with rea- sonable care, considering that ex- act parallel was not available. The application these methods sales contracts other industries, while not discussed here, visualized. THE IRON AGE, May 12, 4 4, ~ PHAIR Associate Editor ROM the machine tool foundries the East and from the famed non-ferrous pattern shops California; from our Canadian neigh- bor and from far away Hawaii, replies THE Foundry Equipment Survey have been pouring for the past several months. Foun- dries supplying information the sur- vey ranged from small shops melting 500 day plants pouring over 1000 tons daily. AGE acknowledges with thanks the generous measure coop- eration extended by.the foundry in- dustry this survey and the many expressions interest made those participating this investigation. hoped that the data presented here- with will some degree contribute fuller understanding basic con- ditions the industry, and, this manner, assist advancing the art founding. previous investigators the foundry field will attest, there re- grettable dearth knowledge con- cerning the productive capacity the industry. Various agencies, notably the Department Commerce, have various times collected material relat- ing production, employment and wages sections the industry. judiciously weighting available data, vey embraces per cent the na- tion’s melting capacity. $4,976,000 for New Equipment Institutional shops, such nical school and prison foundries, and die casting plants were excluded from 42—THE IRON AGE, May 1938 RELATIVE OBSOLESCENCE FOUNDRY EQUIPMENT Scrap pig handling Cupolas Other melting devices Ladles Sand conditioning Molding Core ovens Core making Shakeout Gate cutting and grinding Cleaning Heat treating Dust collectors Electric trucks Welding Conveying AVERAGE Total units, per cent Solid black indicates units installed before 1929 the survey was felt that the in- clusion these groups would tend distort the final figures. According the survey, per cent the equipment use pres- ent was installed prior ognition the trade that goodly portion its present equipment obsolete was given replies the question new equipment expendi- tures that would made operating rates comparable those mid- summer 1937 could again achieved. The amount that would spent under these conditions, reported the plants participating the survey, $4,976,000. This figure includes many rehabilitation and expansion programs that were noted such. many in- stances the replies listed detail the machinery that would purchased and these lists generally agreed with the indications the figures the adjoining page. groups, cleaning and molding equipment purchases would probably account for greater share the expenditures than their numerical frequency would suggest. Next importance would probably core producing equipment, mechan- ical cupola chargers and automatic controls for use with cupolas, ovens, etc. Skip hoist charging devices account for per cent the total number units employed handling pig and scrap metal, and interesting note this connection that cent this amount after 1929, compared with per cent the crane type chargers and per cent the magnets. Trend Portable Equipment Both the sand conditioning and grinding departments there defi- nite trend portable equipment evidenced the fact that both in- stances greater percentage this type equipment was installed after 1929 than any other type the respective groups. present gas equipment accounts for over half the welding and cutting devices use the foundry indus- try. Undoubtedly this predominance may credited the extensive use gas equipment for gate cutting, and also the fact that very little welding production basis. Filter cloth type dust collectors are far the most widely accounting for per cent all dust collectors the industry. The aver- age age this type collector, how- ever, slightly greater than the “all other” classification. This condition, together with the attention that has been focused dust hazards in- dustry, should result fairly heavy expenditures for dust collecting sys- tems over the course the next five Judging from sectional down the returns, the North At- lantic States will spend greater amount money per ton capacity than any other section the country. The North Atlantic States, with per cent the reported capacity, ac- Per Cent Equipment Service Over Purchases Await Recovery counted for per cent the expendi- tures contemplated, while the Central States, containing per cent the capacity, will make per cent the expenditures. Scrap-Pig Ratio particularly interesting phase the survey was that relating the amount scrap iron melted the part the survey were very com- plete and, numerous foundrymen pointed out, the figures supplied rep- resent not but rather average the entire year’s operations. was frequently pointed out that scrap prices bear powerful influence this ratio. Lower scrap prices tend increase the amount scrap used, while high scrap prices have contrary effect. The average ratio all the foun- dries covered the survey per cent pig per cent scrap, ap- proximately one ton refined metal 1.9 tons old metal. arriving relative importance scrap metals indicated the fact that the foundry industry consumes tons scrap iron with each ton pig iron. THE IRON AGE, May 1938—43 MELT. CAP. the money bags show the portion the total expenditures reported the survey that will spent each section the country. Adjacent figures indicate the relationship the melting capacity each section the total for the entire survey. DAILY CHEMICAL ANALYSES ARE MADE PER CENT THE FOUNDRIES PYROMETERS ARE USED REGULARLY THE FOUNDRIES COVERED THE SURVEY IRON AGE, May 12, 1938 COMPARED WITH PER CENT MAKING DAILY PHYSICAL TESTS ONLY PER CENT USE SAND TESTING EQUIPMENT PRODUCTION TOOL malleable and gray iron sections were weighted according their relative importance from the viewpoint melting capacity. Large gray iron foundries, melt- ing over tons day, use per Per Cent Per Cent Total Equipment Before Pig and Scrap Handling Crane Type Chargers .... Skip Hoist Type Chargers. Cupolas 91 Air Weighing Equipment. Other Melting Devices Oil Fired ...... Gas Fired ..... . 65 10 Ladles Mixing, Plain 70 10 Mixing, Teapot ...... . 42 { Pouring, Plain .. 69 76 Pouring, Covered .. 23 10 Sand Conditioning Continuous Systems ...... 55 7 Independently Installed Mobile Blade Type Cutters 68 16 Molding Roll-over, Jolting ....... 86 7 Roll-over, Jolt, Squeezing Squeezers, Plain ..... Strippers, Plain ......... Strippers, Jolting ...... <. 4 Other Types ......... ‘ 67 7 Sandslingers Pneumatic Sand Rammers Core Making Core Ovens Automatic Controls ...... Shakeout Grinding Gate Cutting Wheel Cut-off ............ Band Saw Cut-off ........ Chipping Hammers ...... Cleaning Sandblast Rooms ......... Sandblast Tables ......... Blast Tumblers ....... Plain Tumblers .......... Heat Treating Dust Collectors Steel and Wood Apron.... Per Cent Per Total Equipment Before 1929 Group Welding Gas 55 58 Electric Arc 42 Electric Trucks Other Types ........ 54 44 Core Wire and Gagger Re- claiming Core Wire 56 Gagger ‘ i4 Per cent group equipped. the four types ladles. item obviously not comparable with the other types equipment the group. ‘Comparisons are made on the basis of footage. cent pig charges, while shops melting under tons day per cent pig used. The weighted aver age for these two groups 40.2 pet cent pig against 59.8 per cent scrap. Steel foundries, was anticipated, use very little pig iron, the average being 8.5 per cent the charge. The average malleable casting contains 30.6 per cent pig. Use Instruments collected the use scientific devices control processes lustrates dramatically the that yet remains cultivated this direction. The percentages ar- rived (see illustration) for the various types tests are based numerical frequency. the companies reporting, per cent use pyrometers production tool, but only per cent make fre- quent use sand testing equipment. Chemical tests are used greater extent control the characteristics the finished product than are phys Daily chemical analyses are made per cent against per cent that make daily physical tests. Many the reports stated that tests, usually chemical, are made when radical changes are made the composition the mix. group stated that tests were made only when was required meet definite contract specifications. Considering the short time that has elapsed since the value these tests was acknowledged, the results are more favorable than had pected, the various foundry as- sociations directed toward encourag- ing the use modern scientific instru- ments for controlling foundry opera- tions are deserving commendation this respect. Continued activity this nature should far toward as- sisting the foundry industry pro- duce better castings lower cost. Program the 42nd Annual Convention (CONTINUED 9:30