The Iron Age 1938-06-02: Vol 141 Iss 22

4 FRITZ J. FRANK President J. H. VAN DEVENTER Editor c. E. WRIGHT J. A. ROWAN A. I. FINDLEY Editor News Editor Editor Emeritus Vachinery Raitor Bditor Metallurgical Rditor he, Conaulting Editor Dit, Washington Editor MOFFETT Resident District Editors Pittsburgh Chicago Cleveland Detroit Correspondents London, England Cincinnati Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco SANDERSON Asa ROUNTREE, Toronte, Ontario Birmingham ory Newark, N J St. Louisa ing TURNER Ruffalo fo. Owned and Published by CHILTON COMPANY (Incorporated) Publication Office Editorial and 239 West 39th he. New York, N. ¥ Lis, OFFICERS AND DIRECTORS Fable of the Ow! and the Mice 31 A. MUSSELMAN, President FRANK, Executive Vice-President Structural Welding Progress FREDERIC Vice-President Magnetic Handling and Separation JOSEPH 8. HILDRETH, GEORGE GRIFFITHS. Coupling Sales Research EVERIT B. TERHUNE, nich: ? rre r n WILLIAM BARBER, Treasurer Current Progress Finishing Equipmen JOHN BLAIR MOFFETT, Secretary Acme Installs New Too! Treatment nal JOHN H. VAN DEVENTER ° JULIAN CHASE Casting Sanitary Ware Permanent Molds THOMAS L. KANE W 9 the Communists CARROLL BUZBY Quality Problem Steel Industry > nd. Rate Activity Capital Goods ck- BAUR, General Advertising Weekly Steel Ingot Operating Rate DIX, Manager Reader Service Washington News 0. Member, Audit Bureau of Circulations THE NEWS IN BRIEF 76 nal Associated Business Papers ndexed the Industrial Arts Index. (! Published every Thursday. Subscrip- Plant Expansion and Equipmen Buying | 10 tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single conv, 25 cents. Cable Address ng, New Industria! Literature 114 on- ADVERTISING Just Between Two 134 Emerson Findley, 621 Union Bldg., Clevetan/ D j Herman, Chilton Bldg.. Chestnut roducts Advertised 140 Sts., Philadelphia, Pa. . Hottenstein, 802 Otis Chicage Index Advertiser: 166 H. E. Leonard, 239 W. 39th St., New York ynal Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 239 39th St., New York 1,0. W. B. Robinson, 428 Park Bidg., Pittsburgh Warren, P Rov &1. Hartford. Conn Capyriaht 1938 by Chilton Company (Ine) 7 7 | >. hes ~ 1 and then some MEGA takes the heavy battering jobs its stride. right its element when between air hamme and some hard, defiant material. was specially developed for sisting parts where combination high ductility and hardness required. unbeatable material for both hand pneumatic chipping chisels, rivet heading tools, punches and all simila tools that must stand under drastic, repeated impacts normal tures. Omega only one the complet range Bethlehem Tool Steels. Perhaps your special requirement for die steel with minimum shrinkage, high-speed steel that will stand heavy hogging cuts tough Bethlehem makes these and other each much leader its field Omega. Reference the Bethlehem Steel Guide will aid you the the grade handle your tasks. BETHLEHEM - ESTABLISHED 1855 ... THE IRON AGE JUNE 1938 Vol. 141, No. The Fable the Owl and the Mice HIS week, borrowing fable from the celebrated French author, Fontaine. because clearly reflects present-day situation. Fontaine lived and wrote the century, several hundred years before such modern social philosophers and reformers Jim Farley, Harry Hopkins and Su- preme Kourt Justice Black were born. Yet Fontaine's fable the owl and the mice seems inspired with prophetic knowledge things come and especially some the things that have come pass within the past few years. According Fontaine, and his story said based upon facts, there was once owl that was forehanded the matter providing himself with supply his favorite food. This owl was rather epicure and his favorite diet consisted mice. Being endowed with owlish wisdom, and several centuries ahead his contempor- aries, this owl conceived the idea regularization the elimination cyclical haz- ards and fluctuations the matter mouse supply. had observed that some days, rather nights, when obtained his supply mice, was able better than other nights. fact, some occasions, when was above par pep and eyesight, was able secure more mice than could eat. the other hand, there were times when the mouse pickings were pretty slim either because some slowing down the natural faculties the owl the speeding the natural faculties the mouse family. first the owl endeavored solve his problem depositing the surplus carcasses the mice what corresponded cold storage that day, but his epicurean taste was not satisfied with the rather mediocre results obtained thereby. liked his mice alive and not from cold storage. conceived the brilliant idea keeping them this condition, but subject his command and incapable run- ning away. This was done biting off their feet and then fattening them bringing them plenty food. The mice, course, longer had the ability scurry about and provide for them- selves, nor indeed had they the inclination, being happy have their wants well satisfied. And the owl, turn, had plenty dependent and helpless mice his disposal when needed them. There one technical flaw, see it, fable. The owl did not need bite off the feet the mice. could have made them just helpless the more painless method removing their ambition. live and learn! high and M q “a Structural Wel was only about years ago that the first all-welded buildings and bridges considerable size were erected the United States \merica, and couple years later also European countries Germany. Within this short period structural welding has become well- established practice almost every little doubt the technical, eco- nomical and aesthetic advantages welded construction carried out expert design and well-trained engineers. Structural welding Germany was the first stages its infancy when the writer’s article lished these columns.' those the mere fact erecting riveting attracted attention. Since then, structural welding has passed from its infancy into another stage development which may called the stage efficiency. Welding steel Bondy, THE TRON April 1931 | | | UTSTANDING results large scale research— especially connection with problems fatigue and their influence weld de- sign are outlined this. first series three articles. The welding buildings and railroad and highway bridges will discussed Mr. Bondy forthcoming issues. structures longer done for the sake experiments but only and when the welded structure sonably expected cheaper and better than riveted bolted one. Design for Welding Studied regards the height buildings and the span bridges the United States certainly far ahead any European country. other + + 4 4 + 400,000 sumption, kva. Number Welding Machines 10,000 5000 welding development Germany (International Congress Scheveningen, Holland, 1936). 32—THE IRON AGE, June 1938 ding Progress hand Europe, and especially Ger- many, great care has been taken de- velop the design welded structures, going into the smallest details welded joints which for long time have been neglected. Extensive re- search has been going for num- her years especially connection with the problems fatigue. The following notes are intended illustrate recent developments, not compiling complete list structures which already number many hundreds and perhaps thousands, but discussing some the outstanding results large-scale research and their influence welded design. Ex- tensive practical experience was laid down condensed form the new bridges which will com- pared some respects with the Amer- ican specifications issued 1936. also proposed give particu lars structural welding practice workshop and site, dealing with some outstanding changes the de- sign welded structures extra- ordinary dimensions, discussing also the economic aspects. Increase Structural Welding First all, some significant figures relating structural welding devel- opment Germany. While 1930 the first all-welded railroad bridge the German State Railways with span only ft. was erected near Miinster, Westphalia, there are present more than 150 all-welded rail- road plate girder bridges service 177 ft. single span and 1770 ft. total length. For all-welded highway bridges the present record held single span 338 ft. and total length 3300 ft. All the above figures refer the regards truss bridges there aré none all-welded construction found Germany for reasons which will discussed later. But significant that number truss | | | | | | | 20,000 | 7 7 7 ermany bridges considerable span have been erected many other countries, admirable start having been made the United States 1928 with the famous Chicopee Falls, Mass., bridge. \nother indication the increase structural welding may found gives the proportion the numbers ac. and welders Germany which probably quite different from that other countries owing mainly the proportion bare wire weld ing compared with the use electrodes. Fatigue Factor Included German Regulations welding the problems fatigue resis tance were given little was not until 1934 that the regulations the German State Railways were made include fatigue factor not depending the span the bridge but the ratio between the minimum and the maximum member force. cording that ratio and the num ber trains per day these so-called were laid down and some them are shown Table figures show that the most unfavor factor means increase the calcu lated load per cent with the mild steel 37, while this crease goes per cent with the so-called high tensile steel factor has nothing whatever with the impact allowance which structures exposed movable loads. the y-factors cover the not take into account the different lia bility fatigue cracks joints State Railways, June, 1936 Kommerell, Regulations for all welded plate girder railway bridges, Ber lin, 1936, for Welded Highway and Railroad Bridges, American Welding Clety, 1936 Part I—Research and Design DIPL.-ING. BONDY Consulting Engineer, London, shape. With the publication the latest German regulations for welded plate girder the 2-fac tors were introduced cover the dit ference shape, dimeasions, weld, conditions surface, for given welded joint. the necessary cross section girder equation may thus used: max. o o working stress permissible working stress bending moment modulus tors are taken from tables cluded the regulations, with the result that the working stress -08 -06 -02 Tensile Strength} compared with the stress the parent material the weld respectively. The American figures are based minimum allow- able yield point base material 33,000 Ib. per sq. in. (14.8 tons per sq. in.), and 18,000 Ib. per sq. in. (8.0 tons per sq. in.) the basic tension under the applicable these figures are very near those the regulations other countries, especially Great Britain and Ger- many, and allow for fair compari son between unit stresses for welds Permissible Weld Stresses Compared regards the permissible stresses the weld itself interesting compare the German with those contained the American fications recently The respective figures for butt welds are shown the accompanying Table including also some other countries. percentages given may even considered factors confidence, far they indicate the value the butt weld compared with the parent material. course there are (33 tons per Tensile Strength aday Tension max max TABLE Factor according the BE-Regulations, German State Railways. THE IRON AGE, June ik TABLE 2—Comparison Permissible Unit Stresses Butt Welds. Parent Metal Tons per Sq. In. Country Year Tension Compr. Shear Tension Compr. Shear U.S.A., Bridges 1936 7.1 5.4 Germany, (DIN 4100) Highway 1937 100 (DIN 4101) 6.0 plate girder webs Great Britain 1937 100 100 62.5 8.0 8.0 other butt County 7.0 7.0 5.6 1932 5.1 7.0 .......... 1933 5.4 7.3 3.2 TABLE 3—Quantities Steel Structures Erected for the German State Railways, Quantities Tons 1934 Mild Steel Bridges 30,000 St. Buildings 10,000 H.T. Steel St. Bridges 3,600 Total 43,600 1935 1936 1937 31,000 39,000 21,800 25,000 11,000 10,300 7,600 7,200 1,820 63,600 57,200 33,900 German State Railways: Quantities Structures 1937 many other influences which ought taken into account making direct comparison. Fatigue Tests Large Specimens about four years extensive fa- tigue research was carried out Ger- many large welded and their results are incorporated the new German regulations. was found outstanding importance that the fatigue tests should carried out with specimens considerable size, approach far possible condi- tions practical service. Swinging bridges nearly 50-ft. span were in- stalled for this purpose. These were truss bridges with rotating tester installed the center the upper chords the bridge and the vibra- tions were produced two eccentric masses rotating opposite directions. The test pieces themselves were ft. in. long. The natural frequency the two bridges installed Dres- den and Berlin was higher than the frequency during testing, the latter be- ing 4.0 4.2 Hertz, avoid any dangerous synchronization. The scheme dynamic loading shown Fig. indicating the alternating component stress tons per sq. Dauerfestigkeitsversuche mit Schweiss- verbindungen, Berlin, 1935. Bondy, Paper before the Institution Welding Engineers, The Welding In- dustry, London, March, 1935. 34—THE IRON AGE, June 1938 in, superimposed steady com- ponent stress 7.6 tons per sq. in. the test piece. The swinging bridges were working day and night. electric device there was automatic standstill soon the test piece broke. Most the test pieces did not withstand more than millions cycles which generally considered ample limit for endurance tests structures. Supposing that 100 trains pass over bridge within hours the number millions maximum stress cycles would only reached after service Also for other reasons may as- sumed that with endurance strength based millions cycles are quite the safe side. Influence Test Results Only few the most important results should pointed out, least show their influence modern structural design. Peak stresses are section brings the endurance strength minimum. Fatigue failure oc- curs suddenly without any previous warning, especially places abrupt change section. Butt welds are far more efficient from the point view fatigue than fillet welds. What welded joint often means weakening, shown Fig. Under similar testing conditions the simple V-butt weld showed itself per cent stronger against repeated stresses than similar butt weld “strengthened” welded-on splice-plates both sides. Similar experience has also been had practice, and the designer should always keep mind that the simple butt weld with continuous flow stresses the ideal type Endurance strength also depends largely the proportions shape the member itself. Welded joints same static tensile strength are often quite different regards their fatigue qualities. Butt welds should thoroughly welded the root and pre-welded with thinner elec- trodes. Machined surface may im- prove fatigue values butt welds from 11.4 15.2 tons per sq. in., that per cent. Butt welds oblique- direction stress proved useful and their fatigue values increased from 11.4 14.0 tons per sq. in. Tons per Square Inch ° ° ° Swinging bridge, scheme loading. ° ° ° ee q | 9 7 ' ‘ Side fillets: good elongation the weld metal than per cent essential. Deep penetration may act undercutting and should avoided. Continuous fillets gave better fatigue values than intermit- tent welds (in the new bridge regula- tions intermittent fillet welds are permitted, not even for stiffeners End fillets: concave section fillets are far better than the usual con- vex welds. Undercutting danger- ous acts transversely the direction stress. Covered electrodes prove useful concave weld face secured, Quality Parent Metal Affects Fatigue Strength Moreover, many were obtained regarding other influ- ences the fatigue strength the RIGHT with and without splice plate. Graf). BELOW strength various types girder con- nections. Graf). Type Joint Endurance Limit reversais | | Method | —+ | joint which, apart from the design the joint, also largely depends the quality the parent material, the electrodes and the welding proce- dure. Both electric arc and gas weld- ing were tried this connection. Regarding the German high tensile steel the results were less satis- factory. Substantial advantage using high tensile steels only begins with higher values initial stress. The quantities steel structures erected for the German State Rail- ways during the last three years are shown Table These figures show that the proportion high tensile steel only the neighborhood about per cent the whole consumption. But appears that pre- Graf, Stahlbau, Berlin, Jan. 15, vious with St. have been overcome and many the largest welded bridges Germany contain very great proportion high tensile steel. Fig. gives idea how far the endurance strength welded joint dependent its design. What was ° IG. Sequence work with heavy butt welds. Maximum stress Maximum stress Only tons per Minimum Stress Both so-called butt weld has also been confirmed with series Generally the fatigue strength welded plate girders may as- sumed higher than that riveted girders but one must not overlook the fact that the fatigue strength welds even ideal design still much lower than that the parent material itself. While with regard static tests 100 per cent quality welded joint has been achieved the extraordinary progress made with electrodes and welding procedure, very doubt- ful whether similar progress can expected regarding the improvement fatigue qualities welded joints. Correct Welding Procedure Much care also given the cor- rect procedure carrying out the welding itself. For heavy double V-butt welds satisfactory sequence work was adopted shown Fig. After the first layer has been carried out with thorough penetration thin electrodes the plate girder turned means rotary jigs and the root the weld cut out before proceeding with the welding process. (CONTINUED PAGE 75) THE IRON AGE, June 1938—35 > ful magnet operating from Whiting crane forging plant yard. terials Handling Methods and Equipment. HERE are three very important functions magnetism mod- ern handling work; the first in- volving straight lifting operations, the second involving conveying operations, and the third involving the separation ferrous from non-ferrous materials. Each these functions but another variation the fundamental char- acteristic magnetism; the ability attract and hold iron any shape form. This characteristic itself de- fines the natural limitations mag netism handling work; effec- tive only when the materials han- died are iron, contain iron substantial quantities. tions, however, are such that its use- fields industry. One principle permeates the entire rent electricity passed through coil wire conductor-ribbon surrounding mass relatively soft iron steel, that mass becomes en- dowed, while the current flowing, with the property attracting and 36—THE IRON AGE, June 1938 holding ferrous substances; the current ceases flowing this prop erty attraction leaves the mass inert. consequence, the attraction prop- erty may held under constant con trol. the first category handling (lifting) this idea control fully important the actual property attraction. For, would little advantage handling work have device which picks things up, one could not also make that device drop the things picked up, will. Thus, so-called magnet (or vice which retains its magnetic quali ties indefinitely would not much use handling device. the construction lifting mag- nets, therefore, the mass metal which becomes energized, “mag netized” the flow electrical cur rent selected equally for its char acteristics acquiring and losing mag netic powers, that is, ability quickly take and hold maximum value magnetic flux while the ener gizing current flowing, and 2—the ability give dissipate that flux quickly and completely whey the ener gizing current interrupted. The lifting magnet essentially device depending from crane hoist hook, used for the purpose picking IG. 2—New type four-pole Electric Controller Mfg. Co. magnet for handling coils finished strip steel. ferrous materials shapes which are handle any other way. instance, twisted iron steel turnings, chips from any sort exceptionally hard handle. The lifting magnet, however, will pick huge quantities with ease, for the mag- netism flows from turning from chip chip until the quantity adhering the magnet and other d 1 4 : — q > 2 308 | q Handling and Separation total weight the pull ercised the magnet throughout the mass. Again, the cropped ends hot steel billets make nasty articles han- dle. They are usually dropped into cooling pit filled with quantities steam from the cooling water spray, they are very irregular shape and hence hard grab, and they are usually fairly heavy. But 3—Ohio Electric Mfg. Co. magnet handling three 8,000 coils strip steel at once. dropped the pit the end hoist hook locates number these ends unerringly, picks them and pulls them through the cooling spray, and holds them safely until they are transferred the car which receive them. There, the turn switch the control cab the crane hoist, the energizing rent interrupted, and the ends drop off the magnet immediately. Or, take the newest use which the steel industry putting lifting mag- nets—the handling coils strip steel from the hot mill. These coils are loosely wound; the ends are free, for the coils are not bound any way. And, the edges the strip may have all sorts “camber,” neither the top nor bottom surfaces the coil when up-ended position present truly flat surface. Yet the lifting magnet will lift one, two, three four these hard-to-handle coils with the greatest picking them instantly, holding them dependably during transfer, and setting them down gently required, within FRANCIS JURASCHEK Consulting Editor, The Age reach the crane hook; all care fully though were precious gems. matter what the size shape the article handled, provided only that ferrous metal and not heavier than the handling capacity the magnet used, the lifting magnet will instantly pick up, carry safely and deposit where required. Even bulky, odd-shaped and cumbersome machines may handled the lifting magnet, whereas with any other handling method winded adjustment carefully rigged tackle adds time and expense the handling operation. Lifting magnets are commonly made circular form sizes varving from BELOW Fic. 5—Typical magnetic skelp conveyor, with Stearns roll set slight skew. ——< - é y/ } THE IRON AGE, June 1938—37 > 4—Stearns Magnetic Mfg. Co. high duty magnetic skelp roll. Sy diameter. The largest sizes have lift- ing capacities 65,000 pounds weight single billet slab, 30,000 pounds single ingot multiple coils strip steel, 1800 pounds broken scrap 1200 pounds steel turnings, all day service. Rectangu- lar magnets are also available han- dle rails, rods and structural shapes, where narrow width but long length magnet gives larger area con- tact with the material handled. Temperature weather conditions make difference the handling abilities properly designed and constructed lifting magnet. work equally well temperatures be- low zero almost the melting point iron; dry, dusty atmos- pheres, and below water. fact, lift- ing magnets are frequently used re- cover ferrous metal parts from the submerged cargoes sunken vessels. Fig. shows Cutler-Hammer circu- lar magnet operating from Whiting crane the yard middle western forging plant. The bundle square rods picking weighs close Fig. the Electric Con- troller Mfg. Co. introduces new type lifting magnet especially de- signed handle coils finished strip steel. this magnet the mass the magnetized metal not concentrated over the hole the coil, the usual circular magnets, but placed four points the circumference; two south poles and two north poles. Hence the attractive force comes di- rectly over the coils the metal in- stead over the hole the coil. single coil inches outside di- ameter and weighing 22,000 pounds may handled easily with this mag- net. the other hand the conventional circular magnet shown Fig. (an Ohio Electric Mfg. Co. product) handles three four separate coils strip either directly from the hot mill and therefore unbound; ished, and therefore tightly wound and 38—THE IRON AGE, June 1938 LEFT 6—Dings Mag- netic Separator Co. magnetic pipe roll. ° ° BELOW 7—Two Stearns magnetic pipe rolls set for conveying pipe tubes. one time, each coil weighing Typical illustrations lifting mag- nets handling scrap metal were shown May 13, 1937, page 55; June 10, 1937, page 46, and page 47; Dec. 30, 1937, page 37. Steel mills particular have found magnetic conveying economical aid production. Two general forms equipment are available, each varia- tion the other and based the same general principle. the first, certain the cylindrical rolls roller conveyor system are magnetized (see Fig. view high duty Stearns Magnetic Mfg. Co. skelp roll). These magnetized rolls driven, and turning, the surfaces attract the sheets bars placed the conveyor and move them forward over the adjacent non-magnetic rolls. view typical magnetic skelp con- veyor shown Fig. installed large steel mill. The Stearns magnetic roll here set slight angle the non-magnetic rolls that the skelp-plates are not only pulled forward over the table, but likewise are moved toward the top the table where the vertically-set guide rollers keep them moving straight line. its second form the magnetic shaped with concave face shown Fig. Dings Magnetic Separa- tor Co. roll for pipe tube conveying purposes). The action such pipe roll exactly the same with sheet should noted, however, that pipe may handled both over and under the rolls, since the magnetic force ample hold the weight the pipe section passing the roll any given time. Fig. two similar Stearns magnetic pipe rolls are shown set line idler rolls. also interest note that such rolls will carry pipe, tubes round rods incline well along level stretch. For all forms magnetic rolls the electric current supply must either 110 220 volts. Where alternating current available, the current must converted direct current before can used the rolls. Generally, all the rolls line consume about 500 watts each, and the current continuously except for the last one two rolls the discharge end the conveyor line. Here, order discharge the pipe being handled, the current periodi- cally interrupted, generally means limit switch actuated the pipe itself when has reached the dis- charge position. this point, the current going off, the magnetic rolls instantly lose their powers attrac- tion, and the pipe carried top the rolls continues roll forward and off the conveyor, or, held under the rolls, simply dropped once. Most magnetic are built either 18-in. widths, with the concave trough designed han- dle pipe from in. in. diam- 1- eter equally well. The magnetic at- traction insures positive forward mo- tion, since the frictional contact be- tween the pipe and the roller greater than with ordinary power-driven non- magnetic rollers. The magnetic attraction such rollers clearly shown the shop photograph reproduced Fig. Here two Dings magnetized rollers are holding length steel pipe which five men are weighing all told, with the pipe, about 850 Ib. common use for such rolls, with the pipe held under the rolls, gal- vanizing work. The process extra- enough drain quite thoroughly, and also cool, the pipe end hits limit switch, throwing off the energizing current the rolls. Thereupon the pipe drops from the rolls storage pile below. Two forms magnetic separation are widespread use—dry and wet. The purpose each case separate ferrous particles from quantity loose material, the bulk which may may not have ferrous character- istics. Fig. Dings magnetic separator pulley shown installed 36-in. wide inclined belt conveyor foundry. The sand from the ABOVE 8—The holding power two Dings magnetic pipe rolls suffi- cient carry the weight section steel pipe with five men seated thereon. RIGHT Dings magnetic pulley in. wide sand belt conveyor separates out all the ferrous particles the shake-out sand. ordinarily One end the pipe lifted from the galvanizing tank and applied the under side the nearest magnetic roll. The roll immediately picks the pipe and carries for- ward still other rolls, incline, that the spelter runs out the pipe back into the tank. Having run far shake-out passes over this belt, and the top thrown off shower, shown, onto pile below. The mag- netic particles contained within this sand, however, cling the belt turns around the pulley until such time the belt passes beyond the magnetic influence the pulley. Then these particles, known variously “chills,” “risers,” “shot,” etc., drop away from the belt and into the in- clined metal chute shown. The non- ferrous material screened and then fit for re-use molding sand. Such magnetic pulleys are immense value separating iron and steel parts out any flow loose material which can passed over belt conveyor. The wet separation process used ore concentration work. Crushed ore fed into tank filled with water, through which belt hanging loosely short, distance above the bottom the tank, running. Over the belt and fitting closely its natural sag, long magnet held. the crushed ore and water move with the belt from the intake end the tank for- ward the magnet pulls the ferrous par- ticles the belt, where they cling. Into first discharge hopper the “tail- ings” are dropped; into second dis- charge hopper the “middlings,” finer non-ferrous particles disappear. Finally, over third discharge hopper the magnetic influence stops, and here the bulk the ferrous particles which have all along clung the moving belt, drop off “concentrates.” Bet- ter than per cent the magnetite other minerals having similar magnetic susceptibility may thus taken out the crushed ore han- dled, one operation. THE IRON AGE, June 1938—39 at ° one who interested an- tiques realizes that attained age years practically Coupling Sales Research ZIMMERMAN Vice-President, United States Steel Corp. Delaware ° first half this American Iron and Steel Institute paper, which appeared last week, de- scribed the growing interdependence industry and science during the past decade, and sketched the current status market research and the rela- tionship between sales and research. without significance. Not the case automobiles, where research and development have created markets and fostered sales the limit purchasing power. The Amer- ican chemical industry has grown and prospered because year after year has developed and offered the trade new and improved products, the so- called “test tube babies,” many them prolific family, responsible for mendous volume business. Surely one will think that sales and re- search did not hand hand making commercial progress with all the items mentioned above. Now alertness the part sup- pliers basic materials larly advisable because the fact that new developments scores fabri- cating industries inevitably reflect de- characteristics capital Nine- teenth century merchandise will not fill twentieth century specifications. The good steel rails the gay nineties which performed outstanding service their day, wouid fall far short the requirements modern railroading, just the deep drawing sheets 1908, subject the com mon stamping and forming operations 1938 would the despair the pressman. one would think using the early oil well casings string drilling tools holes that depths two miles more. these latter days 40—THE IRON AGE, June 1938 ° must operate satisfactorily high temperatures, others many degrees below zero; various harden uniformly upon heat treatment, permit welding half dozen methods, and upon specification highly resistant corrosion, creep, abrasion, and surface perfection and ties damping capacity, magnetic and conductance are properties that receive detailed atten- tion. most interesting feature the situation which now operate the circumstance that research one industry stimulated research many others. must maxi- mum progress made, because new outlets must balance new inlets. Moreover, such condition makes the joint between sales and research any one industry operate effectively without expensive lubrication. Suppose, for instance, that the re- search efforts suppliers and users did not have much automobile built the pattern 1938 model, but with the steels pro- curable 1908, finished with the best paints then available, equipped with smooth tires guaranteed for 1500 miles, and dependent upon the gaso- line years ago for its operation, would sad spectacle compari son with what have today. That the situation not depicted due the close cooperation between pro ducers and customers, the interest developing progressively better finished article progressively hetter component parts—and the same token, wider markets for all. the case steel company, goodly proportion the work its technical research organization properly the kind which directed toward the already highly probable needs its consum- ing trade. These needs are known the technologist, either through his direct contact with the field through the eyes the sales department and its bureau market research. this category, which deal primarily with products, are dear the heart the salesman, because any reasonable solution them once paves the way for his regular commercial activities. Here the bond between sales and research quite direct, the backlash may said negligible, because the market position welcome new im- proved product, procurable price which economically sound. Some exploitation may required, course, realize the full measure benefit from development, but the atmosphere itself favorable from the start. Processes Improved Another main section research activity concerned with the devel- opment improvement processes. rather than products. Here the bond between sales and research may not seem, first glance, close, but exists, nevertheless, even though may flexible coupling. Process research, successful, affects prod- ucts either both two ways that are interest the sales de- partment, first reduction costs and second better control and general raising quality. study the equilibrium between slag and liquid steel the open hearth furnace, the subsequent deoxida tion the metal one agent an- other, may seem far removed from the sales manager’s office, vet these features have most important hearing upon the cost properties the product sells. Re- search mold wash, ingot stools, re- fractories, pyrometry, control fur- nace atmosphere, methods treatment, and the like, largely intra-plant company affair, but the long run all this kind activ- ity must inevitably lead sales through the cost sheets and final ac- ceptance tests. Moreover, technical service par ticular value customers often made possible the process research conducted the supplier, because many instances the treats, deforms, pickles, otherwise ° a a | | 3 | 7 handles the steel through operations similar those employed the steel maker. thought just expressed will bear elaboration the following paragraphs. terms service there an- other linkage between sales and re- search, subsidiary the main coupling perhaps, but never outstripped potential usefulness. Considerable emphasis has been placed the fact that the technological activities steel company are continually devel- oping essential information about its products and the treatments which af- fect their properties. Technical Advice Available Much this information used regularly metallurgists and other experts contact with the trade—sales engineers sales metallurgists they supply technical advice and assistance the selection and use their com- products. These men rely upon the homework the organization for their support. They draw upon the research facilities for aid solving problems and are generally reinforced the data and findings the research laboratory. This activ- itv regularly constituted adjunct sales. Now the thought arises, why not expose the entire sales personnel much this same educational ma- terial can readily assimilated and used? The confidence engendered thorough knowledge his prod- uct certainly not handicap the knowing the whys and wherefores recent technical developments. This not say that each conver- sation with prospective customer should start with discussion the iron-carbon equilibrium diagram dissertation rates transforma- sales representative should never embarrassed position because his fund metallurgical information insufficient carry him creditably through enlightened conversation with any those with whom makes regular contacts. Research and sales can profitably indulge siderable intimacy with that thought There still another phase re- search which comes within the scope this discussion even though does not receive its main impetus from either the urgent requirements to- day the readily recognized needs tomorrow. concerned with the possibilities the day after tomor- row. Thus may called long range research, which wise un- fits for mention the same breath with sales, for have seen that sales deeply interested the future. fact sales organization devotes con- siderable effort reading the signs the times and interpreting the auspices. with perfect propriety search. The distinctions which have been used this paper matter convenience and for pur- poses discussion must not looked upon tight and rigid fences, sep- arating research from research. practice there always overlapping and penetration. The motives which guide the work nearby and distant problems respectively, are same, but the degree freedom considerably higher the case the latter. There the research worker attempts look the whole way the horizon, and without binding himself cur- rent products and practices, sets out develop things which present are unfamiliar. Imagination are called into play. considerable amount time may spent the scientific exploration new fields that trustworthy underlying informa- tion may hand support sub- sequent steps, for there are relatively many them taken. Future Markets Considered Along the way however, soon the path seems leading toward the development certain new prod- ucts, the are weighed and discussed with the com- mercial division that parts the course may charted the direction the best apparent prospects. This procedure does not necessarily halt the march toward the still distant ob- jectives, for often advisable follow through and develop something beyond the markets the day. other words the steel industry need not and does not spend all its efforts simply keeping with the demands the trade; justified developing products for which market must cultivated, that may thus contribute, its own name, industrial progress. The exhilara- tion good promotional with new story tell the prospec- tive customer, experience always welcomed the sales department. Its special facilities, including advertis- ing, market research, and sales promo- tion, are always ready lend hand. believe that present methods producing, rolling, and finishing steel are rather ingenious and efficient, but organized research studying radical- different methods the interest finding something better. Almost every operation the steel industry sub- ject improvement year year, due the workings science within and without its confines, but longer in- wrought. hardly necessary add that these wider swings tech- nique are profound interest those who sell the products affected them. Sufficient has been said indicate that sales and research have much common and that one influences the other throughout the whole gamut activities from raw materials tech- nical sales service. The urge find larger markets and new uses for basic materials wholesome characteris- tic the industries engaged pro- ducing those essential commodities. Metal Competition Keen the realm metals alone, has many active companions, may seen glance copper, zinc, nickel aluminum, magnesium and various others. Recently even silver has been much the news, serving notice its ambition reach beyond the confines coinage, jewelry, table- ware and loving cups, and become industrial metal many new applica- tions. making markets for all these companion metals, research, ex- perimental development, promotion, sales and technical service have gone hand hand reach the levels now attained. Neither the urge nor the inevitable competition between and among the metals and their alloys seems abating. Thus the need for continued collaboration all agencies which influence the market position any product quite apparent. From the standpoint the direct customer and the public, one happy circumstance all this effort that makes available choice notably improved and eco- nomical materials for the production finished goods used the consuming trade. this era industrial progress through which are passing there are still many tasks performed, many opportunities for building and marketing better products for the fu- ture. The steel industry, supplier one mankind’s most useful com- modities, undertaking the solution its share the problems, that the world may move forward with steel. THE IRON AGE, June a 5 r ; 2 D r 1 > 1 ! > ; va Current Progress using its own pro- duction for year, the Shakes- peare Products Co., Kalamazoo, Mich., has begun market auto- matic buffing machine small, round parts. Chief among tures stressed that work taken straight into the buffing wheel with equal pressure all critical surfaces, since the wheel quickly shapes itself the part, allowing the buffing plastics well soft metal parts. Using automatic collet chucks and air ejection, production ranges from 300 1000 pieces per hr. and even high- for color buffing. The unit designed attach- ment for buffing lathe. incorpo- rates ball bearing mounted spindle driven chain from 1/6-hp. geared head motor, and single and double- lobed cam for reciprocating the en- tire head and out from the wheel. With spindle speed 360 r.p.m., re- ciprocations are and per min., respectively. Cams may selected knob. Collet capacity in. for the and in. for the contracting, and parts in. time approximately min. Set-up 42—THE IRON AGE, June 1938 MONG the recent an- nouncements the manufacturers, find ap- paratus for facilitating buff- ing and polishing operations, aids for plating, and number items relating spray coating, including water curtain spray booth with unique features. number new finishes are also de- scribed. Straight Line Buffing Machine The Packer Machine Co., Meriden, straight line conveyor machine for finishing variety shapes and sizes parts. The ma- chine can furnished with any num- ber wheelheads, which Packer No. 6500 universal type, with adjustments for setting the wheels any angle from horizontal vertical. The heads are arranged with spring balance plates, compensating for vari- ations thickness the work. Motor Finishing size optional and drive may The conveyor chain driven variable speed unit. The carriers have ball bearing rollers and travel substantial track. All important mov- ing parts the machine are ball bearing equipped and the working parts are shielded against abrasive ma- terials. Sisalin Buffing Wheels For intermediate operations between ABOVE STRAIGHT infeed featured the Shakespeare automatic buff- ing attachment for buffing lathes. Production: pieces per min. ° ° LEFT Packer No. straight line conveyor type polishing and buff- ing machine shown 30% ft. long, but can furnished any length and any number automatic wheel- heads. Rr y d ye ~ Equipment used place cotton buff new patented wheel brought out the Hanson VanWinkle Munning Matawan, The sisal, which material used the manufacture rope and twine, employed spe- cially prepared mat form, interleaved with muslin and the resultant product sewed together. Sisalin sections are recommended for finishing carbon steel, stainless steel, brass, copper and aluminum. Generally, compounds are limited tripoli, stainless steel rouge and emery paste. When compara tively high finish required, dry com- positions are used. Polishing Cements Iding Grinding Com- pound Co., Inc., Milwaukee, marketing two new kinds polishing cements. Idilite aluminum oxide abrasive made two types, whereas Idilon silicon carbide abrasive particularly adapted grey iron. Type Idilite has etched grains which possess high capillarity and sharp cutting qualities. The type non-etched grains possess longer wearing qualities and produce much brighter finishes when used with cements. These grains can furnished any size type. FRANK OLIVER Associate Editor, The lron Age RIGHT water curtain ex- tends the full width the spray booth the Binks Dynaprecipitor unit, which features throughout. LEFT ISAL fiber mat form sewed between mus- lin layers this new Hanson-VanWinkle- Mun- ning buffing wheel for intermediate operations be- tween polishing and buff- ing. Hopper Feed for Barrel Plating Hanson Munning Co. has also developed hopper equipment for the automatic handling barrel plating work. one installation, the dropped into the hopper the first tank and given cold water rinse. then proceeds from one hopper an- other, through cleaner, rinse, acid dip, rinse and thence the plating barrel. After plating, the work handled much the same manner until dropped into Mercil cen- trifugal dryer. The lifting the hop- LEFT HREE automatic hop- per type rinse tanks used connection with batch type barrel plating. The panel provides remote control. This another Mun- ning development pers can effected either hand electric hoist. The hoppers are made either steel monel metal and the capacity varies from 150 For work requiring special treatment arrangements can made reciprocate the hoppers continuous- through in. travel. Automatic lifting and lowering loads can also had through individual motor drives. Carbonate Remover Cyanide plating solutions have tendency build sodium car- bonate, which affects the quality THE IRON AGE, June 7 the deposits and Chemicals division introduced the Pont carbonate re- mover. calcium sulphate compound tion agent which can maintained excess all times, permitting dis- posal the carbonate formed. bulletin prepared the company presents complete analysis the chemical reactions involved well practical considerations. Test for Zinc Coatings determining the thickness electroplated coatings the Hull method, dropping set, consisting stand, burrette tube integral reservoir, Stopcocks are adjusted that the test solution issues the rate 100 drops per min. The cleaned specimen placed deg. and the time the first drop touches the plate until the base metal appears mea- sured stopwatch. second represents thickness deposit in. Accuracy this method within per cent the actual thickness. New Type Spray Booth principle the continuous cleaning paint fumes from spray hooths, has been developed Binks Mfg. Co., 3114 Carroll Avenue, Chicago, and available the new Dynaprecipitor unit. feature this unit stainless water curtain extending the entire width the spray cabinet. Paint ing this curtain are washed down into chemical causes the pigments rise the surface where they may skimmed and reclaimed. Fumes are also drawn behind the water cur- tain the draft from 2-hp. fan the top. This laden air passes through set stainless steel precipitor plates where the pigment deposited. Water LINE roller type turntables for spray booths offered Binks Mfg. Co., Chicago, sizes from in. diameter. Legs can furnished for use with floor type booths. 44—THE IRON AGE, June 1938 under 12-lb. sprayed against these plates from top tom, cleaning their surfaces that they not become gummy clogged. Above the precipitor plates set eliminator plates, the duty which take the moisture from the air before released from the stack. The this cleaning sys- tem claimed per cent. Health and safety are aided consider- ably, and the hazard fire greatly for pumping water from tion pan the sprays, and the water may used over and over. Evapora- tion loss estimated Binks’ engi- neers per cent the volume water circulated the pump, average cost for water 2c. day. The reclaimed pigments may mulled and used paint for odd jobs. Spray Coater for Flat Objects For finishing embossed, stamped and other types flat surfaces that not lend themselves roll brush coating, the Beach Air Brush Co., Harrison, offer- ing its automatic con Gat spray gun, product the Eclipse Air Brush Co., Inc., Newark, made heat-treated Dowmetal and weighs only oz. complete. can operated with either internal external atomization, under low pressure, with width spray adjustable from in. sists rigid framework into which built slideably operated carriage which mounted one more spray guns. The carriage crosses reciprocating motion over the line travel the product coated. Mechanical means controlling the spray intermittently the end each stroke effects economy finishing materials over hand spray methods, The work carried through con- veyor. Exhaust air same way hand spray booth. Spray Guns Binks Co., Chicago, has an- nounced number accessories for spray guns, including the Thor spray gun for heavy materials, illustrated. Where greater capacity than ordinary required for clean- ing compressed air, Binks offering EAVY materials, such asphalt paint and sound deadener compounds, can handled with the Thor model 7E-1 spray gun, made Binks Mfg. Co. the in- ternal atomization type, has ma- terial inlet. two three oil and water extractors combination handles and the three-unit, c.f.m. For capacities 200 the company recom- mends its No. 540 main line extractor with individual extractors each gun outlet. the paint line the new No. 255 strainer serves the last clean- ing agent remove any foreign mat- ter which might have been picked the hose circulating pipes. has 250-mesh screen and attached directly the gun. Binks also marketing twin air and material hose joined the Siameez web. The paint tube made special composition that not harmed the usual solvents paints and lacquer. Each hose re- inforced braids strong cord, an