The Iron Age 1938-06-09: Vol 141 Iss 23

FRITZ President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Wachinery Editor art Editor Metallurgical Rditur Associate Editors JURASCHEK Consulting Editor Washington Resident District Editer- Pittsburgh Chicage Cleveland Detroit Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco Toronto, Ontario Birmingham ALLISON Roy EDMONDs Newark, N. J. 81 Ruffalo Owned and Published by CHILTON COMPANY (Incorporated) Publication Office Editorial and New York. N. Y¥ OFFICERS AND DIRECTORS chin FRITZ FRANK, Executive Vice-President What Machines Are Doing Automobile Workers FREDERIC STEVENS. GEORGE GRIFFITHS JOHN BLAIR Incandescent Electric Carbon Brazing JOHN VAN DEVENTER JULIAN CHASE Accuracy Cutting High-Speed Gears CHARLES BAUR New Aids for Machine Shop Practice April Imports and Exports A HB, DIX, Manager Reader Service THE NEWS IN BRIEF 60 Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. f Published every Thursday. Subscrip- | tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 Single copy, 25 cents. Cable Address. Plant Expansion and Equipment Buying 104 ADVERTISING STAPF Products Advertised 122 Emerson Findley, 621 Union Bidg Cleveland BR. L. Herman, Chilton Bldg., Chestnut & 5tt Just Between Us Two ; 123 , Sts., Philadelphia, Pa H. K. Hottenstein, 802 Otis Bldg.. Chicage 2 Leonard, 239 39th New York Index Advertisers 146 Peirce Lewis, 7310 Woodward <Ave., Detroi: H. Ober, 239 W. 39th st... New York W. B. Robinson, 428 Park Bidg., Pittsburgh D C. Warren, P. 0. Rox 81, Hartford, Conn Copyright 1938 hy Chilton Company (Ine.) gre | } | bal ~ y a | Production Costs Cut with Certified Alloy Steels You can depend better results less time when your heat treater guided the alloy data charts. These charts show him the exact properties the steel with which working and tell him how get the de- sired results. does not have test. takes chances. Spoilage eliminated and sound dependable job high accuracy and uniformity assured. addition saving production costs, the Ryerson Certified Alloy plan benefits the Purchasing Depart- ment they can keep detailed record the exact Principal products stock for Im- mediate Shipment include— Bars, Structurals, Plates, Iron and Steel Sheets, Tubing, Shafting, Strip Steel, Alloy Steels, Tool Steels, Stainless, Babbitt, Welding Rod, etc. 20—THE IRON AGE, June 1938 analysis every alloy purchased. Thus possible duplicate particularly desirable close range specifica- tions repeat orders. The Metallurgical Department benefitted too for they can call for any reasonable physical requirement and sure the Heat Treater can produce the desired result. Ryerson Certified Steels also include carbon, tool and stainless steels that meet definite quality standards. They offer many advantages stecl users. Let tell you the complete story. Write for booklet. Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. Jones sys) steel need the WHEN COMES STEEL FROM WAREHOUSE. THATS WHY JONES LAUGHLIN WAREHOUSE GETS ALL BUSINESS. WILL WISE, KNow ENOUGH, TOO, NOT TAKE CHANCES BUYING STEEL FROM BARGAIN COUNTER SOURCES, RELY JONES LAUGHLIN WAREHOUSE FOR STEEL AND SERVICE WHICH SAVES TIME TROUBLE AND,IN THE ENO MONEY. q Jones Laughlin Warehouses are established order supply you with steel not economically purchasable from the mills, and give you fast, money-saving service. Each Warehouse carries “known products obtained directly from the mills, that you, the customer, need have fear that seconds rejected materials may included your order. Complete records are kept the grade, chemical analysis and physical properties each shipment, you can sure getting right quality steel every time. JONES LAUGHLIN STEEL CORPORATION PITTSBURGH MAKERS HIGH QUALITY IRON AND STEEL PRODUCTS SINCE 1850 MAKING FINER CARBON STEELS FOR NEW AND BETTER USES WAREHOUSES PITTSBURGH CINCINNATI DETROIT NEW ORLEANS CHICAGO 26th and Jane Sts. and Vine Sis. 3289 Beaufait Ave. North Miro and Japonica Sts. 2250 47th Hemlock 1000 Main 2324 Plaza 0470 Franklin 1131 Virginia 1600 NEW YORK, 30-44 Review Ave., Long Island City New York City, Ironsides Jersey City, Bergen 4-2994 Market 3-2994 Operated Jones Laughlin Steel Service, Inc., formerly National Bridge Works MEMPHIS, Auction Ave.—5-1625 Distributing Warehouse for Pipe, Sheets, Spikes and Wire Products. Reinforcing Bar Warehouge and Fabricating Shop FOR EVERY NEED THE RIGHT QUALITY STEEL FULL RANGE SIZES HOLLOW MILLS—National Acme Co., St. Coit Road, Cleveland, Ohio. No. 3802 describes Namco circular type hollow milling cutters and blocks, applications and production results, and sizes for sta- tionary revolving type heads. RUST PROOFING PROCESS Parker Rust-Proof Co., 2177 Milwaukee Ave. East, Detroit, Mich. book- let describes Parkerizing, rust-proof- ing process. The application this process treating such products steel windows, screen frames, air con- ditioning units, sheets, etc., discussed method are also given. STEEL MILL CONVEYORS—Logan Co., Louisville, Ky. New 34-page catalog covers latest developments steel mill conveyors and describes all types gravity and power conveyors used the newest mills. Includes data roller construction, sizes, capacities and other helpful information. CORE BLOWING MACHINES—Osborn Mfg. Co., 5401 Avenue, Cleveland. Catalog No. 110 describes various types pneumatically oper- ated core blowing machines and con- tains installation views, blueprints and box drawing equipment also included this catalog. REFRACTORY Co., Inc., West 45th Street, New York. Bulletin covers Insulag, ing refractory lagging for interface temperatures 2200 deg. F., for directly exposed surfaces 2000 deg. Material may applied hot surfaces and one inch said equal nine inches fire brick insulating value, while having 1/60th the heat storage capacity fire brick for the same heat flow. SOCKET INSTRUMENTS—Westinghouse Electric Mfg. Newark works, Newark, Booklet covers the in- stallation and use sockets that can installed power lines and permit time without stopping the machine interrupting the circuit. Enables engi- regarding power consumption, etc., any time. Booklet also illustrates port- socket instruments and switchboard instruments. BAKING and DRYING EQUIPMENT Gehnrich Corp., 35-10 Skillman Long Island City, Bulletin de- scribes many types gas fired ovens and air heaters for industrial baking, drying and heat treating operations. Among the types discussed detail are indirect gas ovens, recuperative indirect types, and closet type direct heated ovens. Dimensions are given and construction features are discussed detail. LUBRICATION and TRANSMISSION Houghton Co., Third, Amer- IRON AGE, June 1938 ican and Somerset Streets, Philadelphia. Latest issue “Research, Illustrated,” house organ that deals with trans- mission and lubrication cludes discussion the general utility leather, belt costs, lubrication the presence moisture and industrial oil filteration. Striking photographs are used good advantage illustrat- ing the text. PORTABLE COMPRESSORS Ingersoll- Rand Co., Phillipsburg, Bulletin describes three new light-weight air- cooled portable air compressors. Small- est model delivers cu. ft. air per min. Ib. pressure, while the largest provides 105 cu. ft. 100 pressure. Leaf-type spring mountings are employed and machines may towed speeds mi. per hr. safety. SPRAYING and EQUIP- MENT DeVilbiss Co., 296 Phillips Ave., Toledo, Ohio. Catalog covers the company’s complete line spray- painting and finishing equipment. Spec- ifications all standard items are given and several improvements and additions are discussed. CHAIN LINK FENCE—Wickwire Spencer Steel Co., East 42nd Street, New York. New 50-page catalog contains complete descriptions and photographs illustrating link chain fence for all types industrial, institutional and residential property. Construction and specification details are included. DUST COLLECTING SYSTEMS—Kirk Blum Mfg. Co., Cincinnati, Ohio. Bul- letin describes dust collecting systems the metal industries and explains the factors controlling the selection this equipment. Numerous photographs il- lustrate installations and diagrams show construction features. BARREL RACKS and HOISTS—Barrett- Cravens Co., 3255 West 30th Street, Chicago. Bulletin shows the manner which may utilized storing barrels using Barrett barrel racks. Photographs amplify the discussion showing practical adap- tations this system storing. Port- able elevators and lift trucks are also described and illustrated. STEAM and AIR DROP HAMMERS Erie Foundry Co., Erie, Pa. prepared booklet covering Erie steam and air drop hammers. Construction features are explained detail and photographs supplement the text. Ham- mers service various industries are also shown. INDUSTRIAL TRUCKS Elwell-Parker Electric Co., 4205 St. Clair Avenue, Cleveland. technical bulletins de- scribing the F-8 tiering, tilting and telescoping, fork trucks capacities from 3500 5000 and E-2 tiering and telescoping, platform trucks with capacity 5000 Ib. Listed features included dynamic brakes supplementary the travel brakes, ratchets protect the mechanism the bottom down travel and electric clutch protect the mechanism the limit travel and when overloaded. DIESEL and GAS ENGINES—Worthing- ton Pump Machinery Corp., Har- rison, Profusely illustrated 36- page booklet describes various instal- lations diesel and gas engines and gives data relative construction, operation characteristics SIFTING Flexible Coup- ling Co., Westfield, Folder dis- sifting screens single multiple deck, open closed, level pitched models. Machines are claimed particular value where close sepa- ration and elimination abrasive ac- tion material being screened are desired. VALVES and FITTINGS—Walworth East 42nd Street, New York. 602-page catalog covering the com- pany’s complete line valves, fittings, pipe and tools. Includes section giv- ing detailed data types materials used making Walworth products, test pressures and principal dimensions. New sections de- scribe lubricated plug valves, Hi-Test cast iron pipe, fabricated pipe and Walseal. A.C. ARC WELDERS—General Electric Co., Schenectady, Bulletin No. GEA-1750D tells briefly where welding equipment can most prof- itably used, and discusses the claimed advantages, auxiliary devices and rat- ings G-E transformer sets. STRESS-RUPTURE TEST DATA—Timken Roller Bearing Co., Canton, Ohio. The value the recently developed stress- rupture test determining the high temperature characteristics various steels discussed considerable de- tail this booklet. Diagrams, tables and photomicrographs substantiate the discussion, which points out the practi- cal and technical value this test. ro 4 | 4 ... THE IRON AGE ... ESTABLISHED 1855 JUNE 1938 Vol. 141, No. Men and Machines the Automobile Industry better machines and more efficient methods, six workers can the work that required ten —Harry Hopkins. time goes on, there will more and more men unable find employment for technological reasons." Ickes. since machinery has come the real producing agency the world, have had economic —Senator Claude Pepper. "There nothing the proposition that labor saving devices put more people —Representative Hatton Sumners. Here are some very definite and positive statements, spoken with conviction. They are the tenor hundreds other statements which attribute our misfortunes and our unemploy- ment the machine. true that improvement and invention are enemies mankind, should all means curb them. But true? Are these gentlemen and others speaking with the authority facts and experience are they stating assumptions which will not stand under the cold, clear light truth and experience? important that know. For are misled our hope making this better world, into hobbling and shackling the force that has made us, despite depressions, the most prosperous country existence, then shall indeed cutting off our nose spite our face. this and succeeding article which based upon address made John Van Deventer June before the Economic Club Detroit, the author presents factual study what ma- chines are doing workers the most intensively mechanized industry earth. (Article following Page) 208 4 > so — n re > ‘ > > he America are thousands upon thousands machines. They represent the ultimate thus far in- ventive ingenuity, fast automatic operation and high productivity. They form what undoubtedly the world’s modernized mechanization. But outside these factories, and outside the factories and working places all our towns and cities, there army million un- women and children battling poverty and unemploy- What Machines Are Doing Economic Appraisal the Motor Car 200 few years ago. The new cot- ton picking machine, with two can the work 50. The steam try present fairly and fully possible its human record show you what its progress efficiency has done ment. better clad and better fed than was the army Washington Valley Forge, but fighting with less hope its heart. What relation has one picture the Has mechanization, which has proceeded farther and faster the automobile industry than any other, been one the causes which has re- cruited this tremendous army men and women who are without work? There are many who believe that invention and improvement our means production are responsible for this deplorable situation. George said: “In mill and factory, the farm, the railroads and down the mine, men and women are out work reason labor-saving devices. “The great St. Nicholas breaker the anthracite region Pennsylvania, with men, doing the work done *The Governor might have added that this same process has been going for many centuries, ever since the of the wheel and the lever. (Editor.) IRON AGE, June 1938 1910 HESE workers the Packard plant, 1910, rode home trolley cars. They doubtless would have pre- ferred drive their own cars, but economic conditions had not yet made that possible. shovel, with four men, does the work 75. Everywhere, practically every line human endeavor, the story the same. “This wholesale destruction jobs has been going for years,” Earle said, and contends that the danger point has now been reached.* attempt weighing this charge the automobile industry which doubtedly the most efficient duction all the world. this industry today terms man- power versus machine power. going tell you what has done and doing with its amazing and seem- ingly laborless machines the men and women who work and its related industries. going its human material, for that, after all, far more important than what has done and steel. the beginning this century, the entire population Detroit, Lans- ing, Flint, Pontiac and Akron—now typical automotive cities—was 368,000. Today the population cities aggregates more than millions. They have multiplied themselves over five times the past years. Contrast this five-folding popula- tion these automobile cities with the mere tripling population same period Buffalo, Cincinnati, Chicago and New York, with the lesser growth only per cent for the continental United States whole. Evidently during that period great many people came Detroit and its sister automotive cities. They did not 7 - al ‘ t ~ as rou vr Automobile Industry all come once and then stop com- ing. The ingress was gradual sustained, with each ten-year showing larger increment. Some- thing was drawing people there powerful magnet draws iron filings. They came for the same reason that made our forefathers flock Cali- VAN DEVENTER, Editor The Iron Age enterprise. The richest gold field the world that South Africa. During its productive life-time, has far pro- duced total value gold ap- proximately billions dollars. Let see what the equivalent tunity and wages that have sprung from this industry, let paint the economic background against which you can see the picture its true perspective. There are two schools thought which are now sincere but earnest conflict the subject production and consuming power. One school be- lieves that you must have consuming power the form wages other types wealth before you can have production. The other school—and the people the automobile industry are post-graduates that—believes that production creates wealth and hence purchasing power. The doctrine scarcity versus the doctrine plenty. The puzzle the hen and the egg. moment will, believe, make obvi- 1938 WENTY-EIGHT later. Packard employees going home from work, but not trolley cars. Worker ownership autombiles has made the parking lot problem acute our automotive cities. 1849 and the Yukon 1896. They came Detroit because men had discovered gold there—the employment People came Detroit and her sister cities because there was work for them do. There was money ment opportunity and money wages has come from Detroit and her sister cities throughout this land because the automobile industry. But before cite you the amazing figures which record the golden and growing flow employment oppor- ous beyond the shadow doubt that consuming power the effect and not the cause; that production, provided you have useful consumable production, creates the wherewithal finance buying power. Back 1900 when was boy, THE IRON AGE, June 1938—23 4 about one non-farm family ten owned horse and buggy—the other nine afford to. Nor did one family ten then have enough sur- plus buying power have been able afford even the lowest priced auto- mobile today, had such then been available. Today, out every 1.2 non-farm families owns automo- bile. Did purchasing power create the automobile, did the automobile create purchasing power? When the automotive pioneers— Ford, Leland, Briscoe, Durant, and others—first discovered gold the plains Michigan, there was not dollar’s worth employment wages available the industry. started from scratch. Since 1900 and including 1937 there had come from that modest little origi- nal discovery golden flow wages aggregating the stupendous sum billions dollars; wages directly traceable the automobile and which would not have existed except for it. Let analyze the components this stupendous figure. Fourteen billions dollars had gone into the pay envelopes and the salary checks the wage earners and the white collar workers the indus- try itself. Two billion dollars had gone into pay envelopes the steel industry pay workers for making the steel that used automobiles. 24—THE IRON AGE, June 1938 ° ° LEFT DOLF GUSE, years age, planer hand with Chevrolet, with which ° ° ° RIGHT RED BAMBLETT, years age, chrome plater Packard Motor Car Co. Has had years con- tinuous employment with the same company. Three billion dollars had gone into pay envelopes the rubber industry pay workers for making the tires that are required motor cars. Two billions dollars had gone into pay envelopes the petroleum in- dustry pay workers for making the gas and oil that automobiles must have operate. Thirteen billions dollars had been paid road-building labor make the improved roads that were called into being the automobile and which would not necessary except for it. Fifty billions dollars had gone into the wages chauffeurs, truck- drivers, car repair men, service sta- tions and parking lot employees. Think it! Eighty-four billions dollars wages alone years from the golden fields Michigan and spreading its consuming power from coast coast throughout this country. Five times much value taken wages from this apparently inexhaustible employment mine than the value all the gold mined the whole world the same those who believe that wealth creates work, would pose this ques- tion. Where did the wealth come from that created, from nothing 1900, this huge and vibrant system enter- prise which has generated billions wage dollars and which ECHANIZATION has bile industry because hardships which once made here are some who now provides employment one every seven workers gainfully em- ployed the United not obvious when you regard this veritable miracle growth, that created the wealth which financed this accomplishment? Not the work the automobile industry, but work done all our factories and our farms, work done little better each year and little more efficiently. Consuming power did not lead the automobile procession, followed the heels more efficient production. j typic would not claim for moment production wealth. depends what and how done. The first requirement that the product must useful one. The second that must made with constantly increasing efficiency. The automobile industry fortunate that the product highly useful one. met the first requirement. But the industry would not have attained its success, notwithstanding, had not its management met the second re- quirement. the working life span the automo- the workers the physical incompatible. For example, eo Production does not always create consuming power. may destroy diminish it. That happens when the create wealth when build needed roads and highways and build them efficiently can with the most modern tools and methods that have our disposal. diminish consuming power —and wealth—when build them with shovels and wheelbarrows. That bears thinking about these days the “slow down” and the peculiar philos- efficiency. bears thinking about, too, that when thus diminish wealth and consuming power through lessened efficiency are also decreasing em- ployment opportunity. since the beginning the machine age, have progressed to- ward higher and higher standards living, toward higher wages, toward more employment opportunity fol- lowing the basic prosperity formula. The automobile industry stands fore- most exponent this formula. LEFT NELSON, years age, paint striper and sander Packard and with years continuous em- ployment. ° RIGHT McWORTHY, now engaged light assembly and shaft straightening. years with Packard. The basic prosperity simple one. this: More power, better machinery, better output per manhour, higher wages, more cus- tomer value price quality. successful concern which has served broad public demand has con- sciously followed this efficiency formula. And because the automobile industry has followed more closely and consistently than all others, has placed itself the forefront American enterprise and has been the bell-wether that has America out past This basic prosperity formula now being sabotaged. Sabotaged number forces which are working unison though not yet com- bination. Part due our hesitant hovering between philosophy scarcity and philosophy plenty. avowed program wreck capitalism. Part due the rapid growth unionism, which being young, feels its oats and tests its power re- the mistakes and shortsightedness management. But the larger part, far, due the state mind workers who think the standing army million unemployed and who fear join their ranks. The “slow down” you may have heard here although not indigenous Detroit the auto- THE IRON AGE, June tly Ith 00, ich that MAN WEEKS state mind—a worker depression psychology—generated fear the machine. Fear technological dis- placement. There are two kinds technologi- cal displacement which may create un- employment. One aggregate dis- Changes Labor Productivity and Labor Cost Selected Industries from 1929 1936 Per Cent Per Cent Change Change Output Per Labor Cost ‘28 ‘29 WEEKS MAN Man-Weeks Factory Employment per Vehicle Produced body and parts industries included) Years under 3,000,000 units solid Source: Employment from Bureau Labor Statistics; Production from Bureau Census. placement industry, the other individual displacement. The first has with the long term, the second with the short term, Let consider the aggregate displacement first. Aggregate employment considers the industry whole. Employment may industry when the number jobs available that industry bear con- stant relation the total population rather that part the population that between the lower upper working age limits. whose employment automotive industry has continued grow rapid rate even after ing maturity. was full-grown adult 1929, fact, industry that ranked head and shoulders over most and that compared favorably with any other industry our country size and volume annual output. And 1929 was good year for motor car sales. Production that year for domes- tic and export sale was 5,400,000 cars round numbers contrasted with 4,800,000 1937. Yet spite smaller annual out- put 600,000 units, employment the industry was per cent greater 1937 than was 1929. you contrast this with the per cent in- crease the population growth over the same period, you will note that the operation the machines the automobile industry did not destroy jobs for men and women; the con- trary, created new jobs rate times faster than that necessary maintain employment balance. matter fact, figures obtained from the Bureau Labor Sta- tistics employment the industry and from the Census Bureau production proved the astonishing fact that the making each car produced 1937 afforded 5.6 man weeks em- ployment labor compared with only 4.3 weeks 1929. Thus you will agree—you must agree, for the prove both these bases—that there has been technological dis- placement whatever labor the aggregate this industry, but, the 7 q trend greater than the increase contrary, the industry has done more All this portion population creating than its expectable share “take new jobs. industry whose trend the slack” and reduce unemploy- Blast Furnaces, Steel below that such population increase ment. Cotten Goods One would naturally expect rapid will Worsted growth during the early periods ject individual technological new and expanding industry. But the displacement the industry. Slaughtering Meat Packing .......... 5.7 Labor Turnover Age Groups Petroleum Refining ~~ +13.7 —19.5 For Model Years 1934-35, 1935-36 & 1936-37 Rubber Tires Inner Per Cent Workers Each Group Roll +-48.2 Laid Off Resigned Discharged Anthracite Mining Age 1934 1935 1936 1934 1935 1936 1934 1935 1936 Bituminous Coal Min- Group -35 -36 -37 -35 -36 -37 -35 -36 -37 Crude Petroleum Pro- 25-29 26.4 23.3 11.7 7.9 8.7 10.3 2.4 2.5 1.7 +47.9 30-34 21.5 17.3 9.0 7.2 9.0 2.1 Class Steam Rail- 35-39 19.4 16.2 9.4 7.3 6.8 7.3 2.2 +-18.8 —15.7 40-44 19.1 14.0 8.6 6.7 6.3 6.7 2.2 1.2 1.3 Telephone Industry 45-49 14.8 14.8 8.0 5.5 4.5 4.7 1.5 1.3 Source: Output per employee and labor cost 50-54 14.3 9.7 . 8.2 3.0 4.5 3.0 1.5 1.0 4 : per unit of output from U. * Dept. 55-59 11.7 10.2 7.3 3.4 1.5 3.3 2.4 0 a Labor, Bureau Labor Statistics, Monthly Labor Review, November, Over 8.1 7.6 2.3 2.4 3.1 2.3 1937, 1066. Source: Automobile Association IRON AGE, June 1938 | | 6 ish sur ‘37 Sal tell Ba ny ste ar¢ In. no’ sa\ sh pet col pat oft tic ma recent joint meeting the Shefheld Metallurgical Asso- ciation and the Sheffield branch the Institute British Foundry- men, discussion took place regarding the Iron and Steel Institute’s “First Report the Ingot Molds Sub-Committee.” condensed summary this discussion, origi- nally reported and Coal Trades Review, follows: Smith, opening the discussion, said might interest show how important matter was, tell them what investigation Mr. Bacon had meant Steel, Peech Tozer. When Mr. Bacon started his investigations 1932 they were using about lb. mold metal per ton steel for what they called their stand- ard mold, which was then 21%- in. open-top mold. That figure had now been reduced 15% Ib. and the saving the Templeborough melting shop alone amounted roughly $1500 per week. Bacon said would like comment the variation the life molds supplied different makers, particularly the fact that variation had often been put down different prac- tices the shop itself. The mold makers accepted responsibility. Life Ingot Molds cently—a matter five six months ago—they had found necessary take that matter step further and keep the molds definitely batches. That was say, put new molds use and keep them altogether through- out their lives. cracking. thought they might perhaps attaching too portance the question cracking. They found they got the best results when they had per cent the molds failing cracking. they got 100 per cent failure due there was something wrong—the Continuing, Mr. mold metal was too soft too thin. 100 per cent failure cracking, they were making the mold metal too hard the walls too thin. The other point was the effect silicon. They find that, with per cent silicon, higher manganese was definitely Since that time they had stored 1000 molds, all treated the same way, and they had investigated those molds and checked the curve. There were large number molds, course, each point. When they came classify the molds according manganese and silicon, they found that, whereas the high manganese was beneficial with the high silicon, definitely low manganese ficial with low silicon. Binks said noted the original report reference Mr. Affecting the Life Ingot Molds,” and looking through that paper and its discussion the Cleveland (U. A.) meeting the American Institute Metallurgical Engineers, the number mold lives obtained was striking. There were mold lives 250 175 ingots recorded for 17-in. fluted mold, similar gen- eral outline mold, described (CONTINUED PAGE 73) ingot molds filled with steel the Gary works the Steel Corp. THE IRON AGE, June 3 e r - 1 y 4 y y 4 by > — Appraisal Cold Heading HIS the first series articles reviewing the present state the art cold heading. this section, the author discusses the field application cold up- setting, factors relating the relative amount upset, limitations size and ma- terials, and rather com- plete discussion the re- quirements cold heading steel wire, together with its prior and subsequent heat treatment. the second part follow, the general characteristics cold head- ing machines and related cold heading cold up- setting technique particularly applicable the manufacture bolts and capscrews and host special derivative parts where the di- ameter head substantially larger than the shank main body the piece. This condition once estab- lishes its position economically, with- out any consideration its inherently high speed character. screws can now, turned out the rate 225 min. process that competes with automatic screw ma- chine products the one hand and hot forged products and castings the other. Formerly all upsetting was done hot, but largely because the improvement materials, most the commercial metals and alloys are now malleable enough room temperature withstand plastic deformation with- out failure and frequently without the ment. The increasing smoother shanks bolts and cap- screws, free from scale and accurately sized was what brought into existence the cold heading industry. Closer tol- erances have been possible through development more rugged 28—THE IRON AGE, June 1938 and accurate upsetting better die steels. equipment will pointed out. Part will cover ques- tions relating dies, and the fourth and last article will concern itself with the rela- tion die life die heat treatment. The material forming the basis this re- view was obtained staff visits many the leading makers cold headed prod- ucts and supplied cold heading equipment manufacturers, wire suppliers and specialists steels and other materials for cold heading dies. Hand hand with machines and usually goes thread rolling, tremely rapid process that has become accurate enough make Class and Class threads, machines and die materials are improved. thread rolling, while unsupported centers, the shank rapidly rolled laterally between two dies, one which fixed and the other reciprocated crank motion. The forming grooves the dies are straight and are angle corresponding the helix angle the thread. The material the blank not cut, but cold formed into hills and valleys. The fibers the steel, which are the axis the blank, are thereby crimped, adding strength and tough- ness the threaded section. the combined operations, sav- ings from per cent direct labor and material have been made over costs the same parts turned out screw machines. Combination heading, reheading, single and double extrusion offers ave- first blow, coning; second blow, heading; trimming hexagon head and extruding shank for rolled thread trimmer; thread rolled. Sometimes, the extrusion combined with the first heading operation. | — 4 4, 7 parts requiring assembly two three pieces are being produced one piece upsetting machine con- siderably lower cost than they could produced any other known method. fact, some these parts, with offset heads and other projec- tions, could produced otherwise only forging casting. Tolerances cold heading wire, which invariably cold drawn product, are such that pitch diameter stock can specified, although the newer techniques single and double extrusion eliminate this element and save other directions, such re- ducing the relative amount upset. Probably industry has contrib- uted more the development the cold heading industry than the motor car manufacturer, who has been call- ing for enormous quantities stronger and more reliable parts pro- duced lower cost. Although two the automobile builders have installed cold heading departments for part their requirements, these, well ° FRANK OLIVER Associate Editor, The Iron Age Acknowledgment The following companies courteously contributed data their cold forging opera- tions, wire materials, die steels and equipment, from which this series articles was written: Cleveland Cap Screw Co. Dodge Brothers Division Chrys- ler Corp. Ford Motor Co. General Electric Co. International Harvester Co. Lamson Sessions Co. National Screw Mfg. Co. Russell, Burdsall Ward Bolt Co. Manville Machine Co. National Machinery Co. Waterbury Farrel Foundry Ma- chine Co. B-W Mfg. Co. American Steel Wire Co. Bethlehem Steel Co. Carboloy Co. Carpenter Steel Co. Continental Steel Co. Crucible Steel Co. America Jessop Steel Co. Jones Laughlin Steel Co. Ludlum Steel Co. Pittsburgh Steel Co. the rest the industry, have bene- largely from the ideas coming from the bolt and nut makers. ARRIAGE bolt formed double stroke header from pitch diameter wire stock, with the thread rolled right the square underpart the head. Work this type usually performed with spring punch form the cone. result there has been constantly im- proved standard physical proper- ties and tolerances, together with lowered cost. Relative Amount Upset The amount upset usually de- scribed the length the original wire, terms its diameter, that can crowded into the head. Hard- ness the wire one the most important factors relating the amount upsetting. The softer the material, the more readily headed; conversely, the harder the material, the better cut off with clean, 90-deg. cut. The amount up- setting depends also the type equipment and the manufacturing practice. With two and three blow machines, upsetting stock six di- ameters long not excessive. With certain annealing operations and spe- cial dies, even more stock may gathered. One the leading cap screw companies, however, has been able hold the ratio considerably be- low this patented technique. the Kaufman single extrusion process, wire nominal diameter THE IRON AGE, June 1938—29 me die ves gle ect 7 ide es, extruded pitch diameter for the thread section and the head then up- set the usual manner. using wire this size, rather than pitch size, considerable volume stock may upset and for given head size, less plastic flow metal pro- duced. Another type Kaufman ma- chine (not commercially performs double extrusion multi- die, single stroke machine. process, the diameter the wire used usually 1/16 larger than the un- threaded portion the bolt shank. The wire first extruded the nom- inal diameter and the next station, the threaded part the shank ex- truded the pitch thread rolling. Because the bolt head made from much larger diameter than conventional practice, experi- The additional cold working the threaded part, the other hand, gives higher tensile strength and tends counteract the relative loss volume the root diameter. Materials Both high and low carbon steels are being cold headed and some the al- loy steels, including stainless, well non-ferrous materials. The present limit carbon about 0.50 per cent, with the SAE 1035 grade the most commonly used the higher range. the alloy series, SAE 3135 nickel chromium steel and the per cent nickel SAE 2330 steel are quite widely specified. How the steel manufac- tured, its and its surface finish coating are all matters specification and will treated de- tail later this article. The use stainless steel for bolts, nuts, special upset parts, cotters and U-bolts rather common today where corrosion and heat resistance are re- quired, well appearance. One the leading bolt and nut manufactur- ers makes these products two grades austenitic stainless steel, the 18-8 and the 25-12 varieties, the latter intended primarily for high tempera- This company also makes bolts and nuts per cent straight chromium stainless steel. Monel metal another material similar application that being cold for delicate instruments are being cold upset from Invar metal, containing 35.5 per cent nickel and with insignificant coefficient ex- pansion. The aircraft industry call- ing for bolts and nuts aluminum upset cold. New techniques have also been developed for upsetting the 30—THE IRON AGE, June 1938 CCENTRICITY the head makes this brake shoe anchor bolt difficult cold heading job. Made open hearth steel 0.40-0.45 C., 0.70-0.90 Mn. and Mo, this piece headed two-stroke machine with open dies. Part the head formed the punch and part the die proper. The parting line plainly seen. The longitudinal projections the head a.e the air vent channels necessary for proper seating the die. Wire diameter 7/16 in. HIS motor hold-down bolt first extruded twice different from in. wire double stroke, open-die header, with the extrusion des carried the punch. second machine, reheader, the round bolt head formed, and third, the hexagon head trimmed and the second step the shank extruded further. The square shoulder formed cutting tool screw machine. HERE are now three steps required the manufacture Ford valve spring retainer. Mild steel wire, 0.640 in. diam- eter fed into double-stroke, solid-die header, and succes- sively formed into the shapes shown and O.d. the flange in. thickness 5/64 in. reheader, the nib pushed out, blanking the center hole, and second reheader, the piece slotted and the sides trimmed 13/16 the flats. Pro- duction 26,000 pieces hr. rious brasses and bronzes for corro- sion-resistant fastenings. materials with the exception alu- minum are more difficult commercially and usually production confined small parts. Limitations Size the final analysis, will determine the limit the size ma- terial that can cold upset. The cost hot rolled versus cold drawn ma- terial factor that will govern, for example, whether part hot forged cold headed. Questions first cost and size the machine for given capacity will also govern, well the size production runs, which are Canvassing the bolt makers, find in. machine has been built for making rolls for roller bearings, and one the automobile companies has in. machine. One the largest and toughest jobs being run this machine. This upsetting the head kingpin spindle bolt for truck, the size the stock being 1.045 in. diameter. The material exceedingly tough alloy steel with 0.75 per cent Cr., 0.70 q > ‘ — re Mn. and 0.20 Experimentally, the same machine, drain plug low carbon steel being cold headed from 7/16 in. slug into thin rough blank 23% in. diameter. This later trimmed in. hexagon. Steel Characteristics When decision made re- garding specifications for steel for cold headed parts, there are number factors that must taken into ac- count. The function the part, its required strength and toughness hardness usually determine whether grades. Other discussed relate the type steel, either rimmed killed, its inherent grain size, its prior heat treatment, and the type coating desired. Where the cold heading operation the most successful. course, these rimmed steels are available only the low carbon grades and conventionally not greatly exceed per cent carbon content. the onion skin type freezing charac- teristic rimmed ingot, the rim, outside envelope, very low metal- loids and the accompanying greater malleability this very soft skin makes this type steel well adapted for cold heading and especially for roll threading. Automotive applications and partic- ularly high tensile products (95,000 per sq. in. and over) are more likely call for killed steel because the analysis better controlled and there less chance decarburized surface. One bolt company uses this type exclusively. the other hand, rimmed steel sometimes used overcome surface splitting. Surface conditions govern here also, such the presence seams and laps which steps the formation cop- per commutator segments. Cop- per strip, with shallow depres- sion each side, fed into two- blow cold header. the first stroke, the strip split endwise blunt tool and the second blow, the wings are bent back 90-deg. angle. The blanking operation per- formed separately punch press. RIGHT YPICAL embossed bolt head which large amount wire forced into the head cold. RIGHT two drum plugs are typical severe upset. Both are cold headed from low car- bon steel wire rod in. diameter. The one the right, with the projec- tion welding nibs formed the face, has o.d. approximately 154 and head thickness 3/32 in, reveal themselves under the lateral tension created the skin cold headed part. The presence this sur- face tension reason, incidentally, why members that are highly stressed service must heat treated after cold heading. Then again, for some types cold headed products the soft rimmed steel either not hard enough itself does not contain sufficient carbon provide the necessary properties the example certain cold headed components that are given final heat treatment other than that case hardening cyanide hardening. these applications, necessary employ higher carbon steels—up 0.50 the carbon content increased, frequently necessary introduce special features the preparation the wire such “processing,” nor- malizing, spheroidizing. not unusual find necessary certain very severe cold heading work em- ploy processed wire even the case very low carbon steels the type referred above. processing meant the introduction anneal- ing operation just before final light drafting the wire mill. This pro- cedure the wire mill gives much softer stock with bright drawn fin- ish, the respective grades steel, than would result drawing. Normalized wire drawn from rods which have been given high temperature treatment and air cool be- fore drafting. The purpose this an- neal enlarge the grain size the steel and also results softening effect. Both factors probably contrib- ute their own measure the cold up- setting properties. Spheroidizing wire being used more and more where upsets are encountered. Grain Size Considerations Where given component requires steel the higher carbon grades, for example 1035 steel, and where those components are heat treated following the cold upsetting opera- tion, may desirable purchase steel definite grain size charac- teristics order obtain the particu- lar type heat treating response the given conditions may require. Some circumstances dictate coarse grain steel and others fine grain steel. The latter type usually preferred where warpage heat treatment liable prove disturbing factor, particularly the higher carbon steels, and where cracking avoided. Bolts that THE IRON AGE, June wk H 7 — 4 e j 1 ) | are made from fine grain steel require water quench, and bolts coarse grain steel, oil quench. The usual practice today employ the former method for sizes over 7/16 in. and the latter for smaller sizes. Coarse grain steels, Nos. the McQuaid-Ehn scale, have better plastic flow, properly heat treated and are particularly cold heading wires 0.30 0.40 per cent carbon. Rimmed rally have coarser grained outer shell, with more refined core due segregation impurities toward the center the ingot. variation the rimming process, however, which called bottle top capped steel, method casting the rimmed steel which excessive segregation eliminated, and difficult detect skin core center metal. This method casting more desirable where cut threading performed the finished part, due the fact that thread cutting, the tool alter- nately cutting the core and skin. For better machinability, the higher sul- phur steels are called for. Any cold worked material, includ- ing drawn wire, will show finer grain than the hot rolled material from which fabricated; however. coarse fine grain steel re- corded the McQuaid-Ehn compari- son, will still coarse fine far this test concerned, after cold working. Wire Finish Generally speaking, cold heading wire dry drawn stock, particu- larly the larger sizes. the manu- facture dry drawn wire, after the rods have been pickled for scale re- moval, they are given coating hydrated lime which baked the surface the rod and this coat- ing lime which forms the base for lubrication through the cold drawing operation and also the cold head- ing operations follow. cus- heavy lime coating which may may brown rust coating (accomplished subjecting the clean coils fine water spray accelerate rusting) prior the immersion the rods the lime bath. This lime coating, combination sull and lime coat- ing, supplemented lubricants such special wire drawing greases soaps, such calcium aluminum stearate, depending upon the type work. E-P lubricants are also being used. 32—THE IRON AGE, June 1938 Several years ago, the use heavy sull coating was quite prevalent. recent years, however, light sull sull all found most satis- factory. There are other factors considered, however, and the wire producers have coatings meet special requirements. Single extrusion, for example, calls for particular coating and the dou- ble extrusion method much heavier coating, prevent scratching. Closed die work calls for sull lime coat- ing, but for open die work sometimes bright finish desirable. bright so-called liquor finish soft steel wire for thread rolling work produces better results with less wear the dies, although not factor wear heading dies. One motor car manufacturer using liquor finish carriage bolts get the corners square. Soap additional lubri- cant the header. preparing liquor copper finish wire, the wire immersed solu- tion copper sulphate mixture copper and tin sulphate, after which immersed liquor com- posed fermented rye meal and yeast. When drawn through die, such wire assumes the bright finish cop- per copper-tin characteristic color. the discussion above, only plain carbon steels have been referred to. However, many the alloy grades steel are also used cold heading operation (grades such SAE 1300, 3100 and 2300 series). Obviously, the use many these grades neces- sitates special features and operations which must introduced process wire mill operations. The type processing necessarily depends upon the severity the cold upset- ting operation and final characteristics required the finished component. Aside from the more simple types cold headed bolts and screws, would, therefore, advisable for the manu- facturer submit individual problems some reliable maker order obtain the co-operation engineers and metallurgists who are conversant with the entire problem steel making and the application the various types steel cold head- ing operations. Heat Treatment Cold Headed Products first thought, would seem necessary that all cold headed prod- ucts, except very small ones, should annealed stress relieved, but actually this not so. The technique steel making has progressed the point where high internal stress can safely carried. Much depends upon the type product, how will used, how much strain produced the heading and how much strain will added service. Some companies anneal normalize only where the presence sharp corners may start cracks where the part stressed key position, such kingpin bolt automotive axle, Certain parts that are not severely upset and which may require bright finish are not heat treated any Products severely upset, the other hand, may given so-called low temperature draw relieve heading strains. physical properties, such tensile and impact strength, hardness and fatigue resistance are given complete heat treatment, including heating above the critical, quenching oil water, followed draw the desired hardness. realized, course, that cold heading and extrusion the shank raises the surface hardness substantially due the cold work. Cyanide case hardening quite common method treating cold headed parts subject wear. Controlled Atmosphere Furnaces Favored until rather recently, annealing was done atmospheric naces, necessitating subsequent pick- ling, washing and drying operations. The latest installations, however, em- ploy furnaces the controlled at- mospheric type, eliminating pickling. tained the partial combustion natural, manufactured coke oven gas. Most the installations are electrically heated and completely con- veyorized. the other hand, the Homo batch type furnace tically standard throughout the indus- try for drawing operations. very large work, running over in. diameter stock, subsequent heat treatment almost invariably neces- sary. the truck kingpin, for ex- ample, which has been mentioned, the piece normalized relieve the cold work strains and then given cyanide case for wear resistance. An- other heavy piece made the same motor car manufacturer later butt welded propeller shaft tube. The material 0.40 C., 0.80 Mn. steel, which normalized 1500 deg. F., quenched and drawn 700 deg. Brinell hardness between 387 and 444. This typical example cold headed part for severe duty application. >: several years has proved the merits incandescent electric