The Iron Age 1938-07-21: Vol 142 Iss 3

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Bditor Metallurgical Editor Associate Editors JURASCHEK Consulting Bditor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Newark, N. J. St. Louis TURNER Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Offices Philadelphia, Pa. 239 West 39th St. New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS. EVERIT TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS CHARLES BAUR CARROLL BUZBY FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh Warren, Box 81, Hartford, Conn. 21, 1938 The Saga Johnny Bernal Industrial Plant Mobilization for Next War Getting the Most Out Cold Heading Dies Die Castings Hardware Production Hard-Facing Problems Today New Designs Electrical Equipment Casting Ring Gears Centrifugal Molds Automotive Industry Statistics Metal-Working Activity Washington News THE NEWS BRIEF Rate Activity Capital Goods Weekly Ingot Operating Rate Plant Expansion and Equipment Buying New Industrial Literature Products Advertised Just Between Two Copyright 1938 Chilton Company 122 ‘ic or st st 7 Is O- it. to re st. he nt ils ut 4 | to ist ill Ww st in- j 48 ; | 3 ily . til 0,- ile 60 ral ed be Makes Ryerson Certified Steels Still Better Buy With the recent lowering steel prices, Ryerson Certified Steels offer you still greater value for your steel dollar—high- est quality year after year uniformity accurate heat treatment data every bar selected alloy steel all the new lower prices. Ryerson Certified Steels are controlled definite specifications that assure the most desirable features each particular type steel whether easy machining screw stock, deep drawing quality sheets highly finished stainless. the alloy steels, only whole heats conforming certain narrow range anal- 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. 24—THE IRON AGE, July 21, 1938 yses are selected for Ryerson stocks. Bars from every heat are analyzed, heat treat- and tested. Data sheets showing the exact chemical and physical properties and results the heat treatment tests are prepared and sent with every shipment. They are accurate guide quickly securing any desired heat treatment result. These plus new low prices make especially advantageous concen- trate your steel purchases with this one source. Stocks are complete and Immedi- ate Shipment assured. you not have the current Ryerson Stock List, will glad send copy. Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. | | q | ‘ ‘ | ESTABLISHED 1855 The Saga Johnny Bernal ... THE IRON AGE ... JULY 21, 1938 OHNNY BERNAL not viking. Yet has saga such viking might envy. Vikings, repute, were big men physically. Johnny big man too, although stands about four feet six. Until last week, had not seen Johnny for years. The last time saw him then was standing soap box that could tall enough reach polishing wheel which worked for the Buffalo Forge Co. Johnny was then years old, young, whichever way you want put it. Quite way beyond the year that some people like talk about. And had been working for the same company for 31! years. That was years ago, when left the superintendency that company enter the field journalism. lot water has gone under the bridge and over the dam the meantime. We've had World War, and three depressions during that quarter century. And people's ideas have changed during that time too. Effort isn't fashionable was once, and people have come believe that the world owes them living. Last week, annual picnic Buffalo Forge and associated companies, the first one have been able attend for quarter century, met Johnny again. Eighty-four years old now and still working for the same company. But the inspection depart- ment. Fifty-six years with one company. That's what you might say was pretty job. Johnny could have retired pension years ago had wanted to. But has old- fashioned ideas. likes work. During his years effort, Johnny has helped make lots things for many thou- sands people use, profit and enjoy. People all over the world owe something Johnny. What grand thing would had some sort television that Johnny could see and know the useful results years honest and capable effort! I'll say that Johnny has saga. viking ever did much good for many people. And what about the social usefulness company that has been able provide Johnny and others with steady jobs for more than half century? That something saga too! Vol. 142, No. 7 rs t. be 7 l- 4 next war will war metals. will battle be- tween the metal working indus- tries the world. Success the next conflict will crown the efforts the nation with the best industrial mobilization its metal working trades. The last two decades have changed the entire com- plexion modern armies with the emphasis not upon man power, but upon machines The tonnage metal used combat units has vastly increased over World War conditions that the load industry will immensely greater than 1918. Metals Versus Man Power Let look practical example The First Cavalry (Mech- *These figures are substantially cor- rect. The exact figures are process change. 26—THE IRON AGE, July 1938 COL. TOULMIN, Jr., D.S.M. ° ° ° anized) the United States Army, with strength approximately 800 men, has the capacity deliver small arm fire upon the enemy equal that World War Division 22,000 men.* place 22,000 soldiers, have the mass effect two and one- half million dollars worth scout cars, armored cars and combat cars. Metal tonnage has taken the place men. have motorized machine gun car- riers and rolling repair vehicles for repairing automotive equipment and ordnance. have great masses machine guns. have motorized artillery instead pulling horses. brawn and metal for man power. And all through the Army, now have, foreign armies, the mechanized, robot division. Our new division will have approximately 13,000 men, con- trasted with World War division 22,000 men, with greater proportion guns, trucks, tanks and armored cars make for less man power. The old infantry regiment had 3106 transport; now has 2472 men and from 600 800 tons transport. has increased its machine guns from 140 and its automatic rifles give fire power equal 7300 men with the Springfield rifle—and takes this metal tonnage move the ammunition for such amazing fire. The cav- alry regiment boasted tons trans- port and 1441 men with machine guns; the new mechanized regiment has 817 men, 521 machine guns and over thousand tons transport and mechanization. 7 Mobilization for The Next War-- the old days division did well does 60. The new units deliver per cent more metal with per cent less men. Now have for 1000 men compared with the old outfits. Everywhere you look modern army, you notice tanks, trucks, mo- tors and powerful weapons machine- carried pulled. The individual, soldier, has become completely sec- ondary: indeed, you have look find him modern army. The whole tempo war accentuated its the World War, our mm. gun had effective range 7500 preparation the best preventative war. adequate preparation today means the most efficient possible mobilization indus- try and particularly the metal working industry. For the next war will war metals. This conclusively demonstrated the accompanying article Col. Toulmin, Jr. discloses the amazing trends and progress military mechanical modernization since the World War. Should America called upon play part another major conflict, will found far better prepared for than was two decades ago, and primarily because the effective organization our industries, plus the re- markable development ordnance design and production methods. ° ° ° means new class metals and metal Our anti-aircraft guns are automatically calculators now 15,000 yd. the World War, our 155 mm. Howitzer had range 12,000 yd. and now has effective range 26,000 this working. mechanical which gage the speed and bd te. San Antonio Division Tests, held San Antonio, Tex., fall 1937. , Tanks Tank Company operating with opposition force. THE IRON AGE, July 1938—27 4 Combat car Ist Cavalry, altitude the airplane target, deter- mine the fuse setting and control the fire the 3-in. shells 100 min. Both guns and searchlights are syn- chronized. Thus have reduced man power and enormously increased the tonnage metals per man. Industry generally with its own domestic problems has failed realize this sweeping revolu- tion the art the successful prose- able industry that spells success mechanized conflict. Modern armies subsist industry and only because industry. Indus- trial mobilization the metal trades the very essence successful war. What more important, the key itself not having war. The nation that has effective mobilization its metal trades the nation that prob- ably will never have the occasion use its manufacturing facilities and its armies. Mobilization Organization The War Department, under the direction Col. Louis Johnson, the Assistant Secretary War, has de- veloped vast organized plan in- dustrial mobilization for making war. The Army wisely realizes that the whole success its program depends upon what industry does about because now have “machine now make our 28—THE IRON AGE, July 21, 1938 mechanized, Fort Knox, Ky. fighting soldiers the foundry and machine shop: not the duel field. will too late the next war organize General Munitions Board and War Industries Board the leisurely fashion such did dur- ing the last World War. Colonel Johnson and his ciates have provided machinery for gearing industry the Army and making this “war metals” effective before the first shot has ever been fired. this, the Assistant retary War charged law, under the National Defense Act, with organizing the plants the nation into munition producers, minimum interruption the civil life the nation. His office provided with Allocation Branch and Planning Branch organize industry: and Industrial War College for the training Army leaders the art the mass production munitions and the control industry for the manufacture ammunition, artillery, tanks and all the metal gadgets war. Instead waiting until be- come involved conflict create our organization, there been created frame-work the management our vast industries for the production munitions. Machine Gun Squad. Doughboy Machine Gunners the District ington’s Battalion the 12th Infantry, putting the machine through little voice culture. Oct 31, 1937. +, > There War Resources Adminis- tration, with Legal Division, Policy Division, Administration Division, Liaison Division, Facili- ties Division, Transportation Di- vision, and Power and Fuel Division. There War Trade Administration Price Control Committee; Selected Service Draft Administration; War Finance Control Commission and War Labor Administration. Allocation Production the beginning the last war, one our principal difficulties was the competition between the Army and Navy for production from our plants. This all changed now, under the National Defense Act, the Army and Navy, advance war, decide upon division each plant, plants, between themselves. The Navy takes one plant and the Army another, they share some predetermined agreed ratio the productive facilities particular plant. After this general allocation plants has been made, the Assistant Secretary War, effect, says this each potential munitions maker: “We would like survey your plant see what you can produce that comes within our munitions schedule what want. Let sit down together and see what your plant can do. will then allocate your plant sched- ule production how much you can make, what you will make and what you will need make it. will sign memorandum expressing our understanding will know can rely upon you time war. prevent upsetting business gen- erally, are only going take twenty fifty per cent your ca- pacity when war comes.” Working along this reasonable line, Army officers have surveyed more than 10,000 firms. They have studied the facilities these firms. Each Corps the War Department, whether the Quartermaster, Ord- nance, Air Corps Signal Corps, has had its experts look over each plant and they have determined between themselves what particular branch the Army can have its needs filled that particular plant. The War De- partment representatives and the rep- resentatives the firm have worked out tentatively what can done that particular firm. When war comes, the firm thus sur- ta q First Army Maneuvers, Pine Camp, August, 1935. Christie Tanks, Company, 67th Infantry, Ist Division Maneuvers. veyed, having its allocated schedule production, will know exactly what will already have studied out its plans carry the industrial burden mak- ing war. the list, its needs for priority materials will have been calculated and provided for. WORD ABOUT THE AUTHOR ARRY AUBREY TOULMIN, outstanding authority the status our national defense. During the World War was successively assistant secretary the General Munitions Corps the Council National Defense; cap- tain the U.S.R. Ordnance; ordnance, acting chief aerial armament division the A.E.F. France; lieuten- ant colonel the Air Service and as- sistant chief the staff the Air Ser- vice the A.E.F. France and chief the coordination staff. Keeping his in- terest military affairs since the World War, now Colonel the Engineers the United States Reserve Forces, deputy chief the staff the Ohio Military Area, and colonel com- manding the 329th Infantry the 83d Division. His civilian career embraces distinguished record patent attorney and author. Plants” More than that, will probably have had what the British call “shadow set the factory. This means that many factories there going set complete smail plant equipment for producing the particular munitions that that plant going turn out time war. This sort “experience plant” let the management find out what are the problems solved small scale before they are called upon suddenly make the same munitions large scale. This so-called “pilot plant” rep- resents one the fundamental ideas the Assistant Secretary War. Colonel Johnson, make ready overnight. These allocation schedules not only eliminate duplications and competition between branches the service, but they very carefully list the location, financial rating, business affiliations, the number skilled workers. Also such study compre- hends what new construction will needed remove bottlenecks pro- duction, what electric loads, what in- creased power facilities will needed, what housing for the increasing num- ber employees and all the other factors that must considered stepping munitions production for civilian plant. (TO CONTINUED) THE IRON AGE, July 1938—29 try: the WY ; eady for AS, + cold heading steel wire, not uncommon for the tool pressures any tool steel withstand. other words, great deal this work actually being done beyond the strength capacity the This made possible preloading the tool the direction opposite the stresses service. For example, solid cold header die subjected enormous bursting action. Either jackets can shrunk around the im- pression preload the hole, the same thing can accomplished with properly designed quenching fixtures. compressional stress 150,000 Ib. per sq. in. the hole solid header die means flush quench. This means that the first 150,000 Ib. bursting stress service and the full strength the steel available beyond this point. The manner which the tool de- signer tackles the above have important bearing the type tool steel must use. general, can one three things: can ignore preloading gether both design and heat treat- ment. so, his heading machines will limited the less difficult types work. Tools made are very likely tempered (or drawn) after hard- ening rather low hardness value. Quite frequently the tools are drawn soft enough ream the hole and may show anywhere from C-50 C-59 Rockwell. Both the wear resistance and the strength the tool are limited, and this limits the type work that can undertaken, and the production secured from each tool. can make composite tools shrinking pressing outer jacket over hardened core. Many types carbon and alloy tool steel have been used (with varying degrees success) this method. Even high chrome steel cores have and occasionally used. This method can course used only for solid 30—THE IRON AGE, July 1938 header dies and has application gripper dies. can build favorable in- ternal strains hardening the tools suitable quenching fixture. Since strains useful magnitude tool steel, there virtually only one tool steel general use such plants. This must substan- tially plain carbon tool steel, usually containing from 0.80 1.10 per cent carbon. This type steel hardens first three articles the series appraising modern cold heading prac- tice Frank Oliver, asso- ciate editor, The Age, covered the fundamentals and laid the groundwork for better understanding this detailed study Mr. Palmer factors affecting die life. describes meth- ods preloading dies in- crease their useful life and discusses the various types die failure and how they may overcome proper heat treatment. intangible factor timbre tool steels also analyzed. The earlier articles appeared the is- sues June and and July only the surface and supported underneath tough core. Any alloy the steel which would cause harden more than say in. deep, ruins the steel for this type work. Carbon steels containing about 0.20 per cent vanadium are eligible, but are not nearly popular the plain carbon types. This procedure, and these steels, are applicable solid dies, dies, and header punches. Without having any accurate fig- the Most Out Cold guess that least per cent all cold header tools fall into Class and use substantially straight carbon therefore confined this Types Die Failure That all cold heading tools ultimate- fail service obvious. The rea- sons for discarding them may grouped under four definite heads. The loads service are too great for the strength the tool and splits outright. illustrates failure this type. Under repeated hammering, the hard surface caves the tool will spall somewhere the failed this manner. Small pieces will chip out. This usually happens corner shoul- der illustrated Fig. The chips are much smaller than which spall out failure No. and chipping likely occur early the history the die, usually occurs after amount service. Sinking and spall- ing can frequently identified carefully measuring the parts just be- fore failure and finding enlarged tions the work where the tool has started sink. Chipping, the other hand, usually proceeds from tool that fully size and shape. The tools may wear oversize. This the way all tools should ulti- mately fail, but this desirable end can achieved only when none the first three types failure occur. The causes and cures these failures will now discussed. has already been mentioned that plain car- hon (or carbon-vanadium) header die steels harden only the surface. This hard shell, showing perhaps C-66 Rockwell quenched, may penetrate in. less. Below this there tough core having Rockwell hard- The penetration hardness any given tool can controlled, within limits, the hardening temperature. : 7 1 4 the itely the pper hips eces and the pall- sec- has ther tool can the has die rate any ure. Heading Dies good header die steel can hard- ened anywhere between 1450 and 1600 deg. The higher the hardening temperature, the deeper the penetra- tion hardness, and also, the higher wil! the hardness the tough core. The progress this procedure can Assuming that the tools have been optimum internal strains: (a) Tools will split when the hard- ness penetration too The remedy lower the hardening tem- perature until splitting stops. (b) The tool will sink spall when the hardness penetration too shallow. The remedy raise the hardening temperature until spall- tioned and etched die that has just started crack result sinking the shoulder. Note the relatively shallow hardness penetration compared Figs. and Otherwise, this die presents beautiful hardening pattern. (c) Tools will chip they have improperly insufficiently tem- wee solid header die split service due excessive depth hard- ness. Section smoothed and etched show hardness penetration. Dark areas are hard, light colored areas are soft. PALMER pered (or drawn) after hardening. brittle (or perhaps structure the steel, and corrected soak the drawing temperature. the tools not fail any the above three processes, they will wear out. Some people take the short and easy route this desirable end using the practice first mentioned method No. However, their dies are soft, and they wear oversize rap- idly. quite evident that, other things being equal, harder die will outwear softer die. The trick getting maximum hardness (without perfect the flushing equip- ment that maximum favorable internal strains are developed. Obviously, this 2—A gripper die that spalled service. reduces the requirements for strength and toughness the steel itself and permits the use harder wearing sur- faces without failure. The best prac- tice will leave the working surfaces the header die about C-61 C-63 Rockwell hardness. will readily appreciated that the above program throws quite weight responsibility the manu- facturer tool steel for cold header dies. the first place, his steel must very clean, sound, and free from all internal defects that would become starting points for failure under ex- Assistant the President, Carpenter Steel Co. solid screw header die failed chipping although showed ideal hardening pattern after had been sectioned and etched. cessive operating loads. tion best assured using the hot acid disk All cold header die steel should subjected the hot acid test the steel manufac- turer the customer, both. Com- plete instructions for making the hot acid etch test are given the Na- tional Metals Handbook, Tech- nical Bulletin the Carpenter Steel Co. Timbre Tool Steels Since the life header die de- pends such large extent upon the exact penetration hardness, quite important that each and every bar alike this particular. now quite generally recognized that two bars steel may have the same chemical analysis, they may sound and free from internal de- fects, and yet they may have differ- ent inherent penetration hardness. steel may harden quite shallow, may harden quite deep, may harden anywhere between, shown THE IRON AGE, July all rea- 5 — Brine Rockwell Rockwell quenched from Case Core 1425° F. C-67 C-40 1500° F. C-67 1550° F. C-67 C-47 1600° F. C-67 C-50 4—Shallow hardening carbon tool steel—samples in. round—showing effect hardening temperature pene- tration, and core hardness. heat treatment ascribed prop- erty the tool steel variously referred timbre, personality P-F char- Anyone who has ever done much work cold header dies familiar with the following situation. certain brand tool steel will procured and perhaps made into header dies. After certain amount experimental heat treating, pro- cedure will finally arrived that gives reasonably satisfactory results. this time, the bar has been used and new bar has been procured— presumably, exactly the However, when dies are made from the new bar and heat treated like those made from the first, they give practically production and the heat treating problem must worked out all over again. This due variations the timbre the steel from one shipment another, and makes for nothing but trouble cold heading plant. Timbre heat characteristic— that is, the timbre uniform through- out any given melt steel. This property can controlled the steel maker and can deliberately melt batches that will harden the depth that wants. manufacturing header die steel, certain timbre steel must adopted the manufacturer, 32—THE IRON AGE, July 21, 1938 and must then stick rigidly this same specification that his bars header die steel will “interchange- able” the hands the customer. This very recent development the manufacture tool steel and has made possible tremendous strides the manufacture cold heading tools. Instructions for timbre testing are given the National Metals Handbook, can found Tech- nical Bulletin the Carpenter Steel Co. conclusion, word should said about trying out new grade header die steel. not uncommon for buyer say tool steel sales- man: “All right, send piece your header die steel about in. long, and will make couple dies and try speaking. this waste time for both parties. would the merest luck the proper heat treating were applied these first two tools. There not enough material available work out the proper heat treatment for that particular kind tool steel, and satisfactory results can expected unless this done. the writer’s opinion that buyer header steels satisfy himself the ability new vendor supply steel that clean and sound, and steel that in- terchangeable its hardening char- 5—Too shallow hardness penetra- tion caused sinking and cracking the shoulder this solid header die, shown sectioned and etched. Shallow hardening timbre Medium hardening timbre Deep hardening timbre samples from three dif- ferent lots carbon tool steel, hard- ened 1550 deg. Analysis the same, but the hardness penetration different, because the timbre different. acteristics from one lot should then procure enough steel enable him intelligently work out the heat treatment that will give maxi- mum production for certain tool and certain job. This heat treatment will different for different cold heading operations, must stick one job and one tool steel until feels that its possibilities have been exhausted. mill that has manufactured much header die steel equipped after has failed and assist its cus- tomer applying the proper correc- tives. type tooling greater tax the ability the consumer, the ability the tool steel manufacturer, and the resourcefulness both, than are cold heading tools. The writer has seen production given header die gradually jacked 1000 per cent the patient and consistent application the principles set forth above. 7 7 . Ge 4 advanced practice hard- ware manufacture, especially the production locks numer- ous types, doubtful the pro- cedure the Yale Towne Mfg. Co. can matched. Although the com- antecedents date back more than hundred years, production facilities are kept right the min- ute. They include foundries for sand casting all the common metals, de- partments devoted stamping and equipped machine shops, forge shop, several tool rooms and lastly, one the largest and best equipped die cast- ing departments the East, and one which the intricacies the dies employed can scarcely equaled. addition there are departments devoted finishing, including electro-plating and the application many organic finishes. varied and well organized, sig- nificant that the departments con- cerned with the initial production die castings and with subsequent oper- ations these have grown rapidly. They account for important and ever increasing proportion the com- output. This trend has not been because any predilection favor- ing die castings, since other methods production had been profitably and efficiently established long before die casting was considered. re- sult, rather, keen perception the Die Castings Gain Ground Hardware Production— ° ° HERBERT CHASE ° part die castings are destined play the hardware field and resolve meet the type competition which they are becoming increasing im- portance. this end, the die casting department was established some five years ago and daily demonstrating its ability turn out precision cast- ings low cost. Today, this department makes use die casting machines, which all but three are type designed and produced the company for its own use. All these are operated exclusively high-purity alloys the Zamak type, the No. grade being used exclusively present. Low cost, ease casting and excellent physical properties for the specific ap- plications are the primary reasons for using the zine alloys only die cast- ing work. finished products, the die castings are combined, course, with parts many other metals worked other departments. Intricate Coring Required small measure the success at- tained with die castings attributable well designed and extremely well built dies, some these being ex- traordinary complexity because the intricate coring required many the small lock parts general, the dies have several cavities and often they are fitted with several strictly interchangeable parts such are needed for rights and lefts, for ° numerous key changes and for special requirements different customers and different designs lock. Cores are all made for automatic operation and many them require dozen more small parts which sometimes are required interlock. Moreover, dimen- sional limits plus minus 0.001 in. have held the castings and some these dimensions, being de- termined parts the die having motions relative each other, require exceptionally fine job fitting die parts, well provision for adjust- ment certain parts. Despite high initial cost and much upkeep work, the need only minimum ma- chine work makes such dies good investment. Few details regard dies can given, but some idea the problems involved can had reference the accompanying illustrations cer- tain dies. Sections thin 0.015 in. are cast between movable cores some instances. Wherever feasible, several parts the same assembly are produced the same die, which some- times yields many score small castings single “shot” the casting machine. This one many items contributing economy die cost. All dies are hardened, this essential maintaining the de- gree accuracy needed when parts have relative motion. The closest possible coordination maintained, THE IRON AGE, July 21, 1938—33 | f . ill to = C- r, iS ie Kipcaster, which used for dies in. square, shown form- ing the gates five small cast- ings shown the foreground. Dies are opened and closed with the handwheel, but are locked air piston. About 400 450 shots hour are made with this ma- chine. course, between the die shop and the casting shop, well between the designers the parts produced and the dies make them. Machine Characteristics the Yale Towne die casting machines, dies are opened and closed vertical air-operated piston actu- ating toggle mechanism. The rear die head slides two tie bars, one above and one below the axis the machine. Toggle pressure mitted links which bear near the four corners the head. Metal in- for produc- ing eight plugs (seen gate fore- disman- tled show the the core and other parts re- quired Core parts are made interchangeable and are arranged for automatic operation. Slides shown just below the main die body the right background carry many dozen cores for making the trans- verse holes the plugs, some which are spaced only 0.015 in. apart. exerting average about 1200 per sq. in. the molten metal. The latter maintained, automatic con- trols, the temperature found give the best castings from the particular die use, generally about 780 deg. Molten metal ladled into the metal pot from supply wagon which brought from adjacent melting room. the machine can operated 400 more cycles hour, average about 300 main- tained rule give time for proper operation cores, for hand ejection and for such inspection the gate castings conditions require tain uniform product. The gaged least once hour make sure that proper dimensions are main- tained. Every effort made pro- duce castings maximum density and smooth surface finish avoid rejects and minimize polishing and buffing costs. Safety Paramount Especially noteworthy are the pre- cautions taken for safety comfort casting machine operators. 3 4 ‘ mechanism such way that the metal plunger cannot operated until the dies are not only closed but secure- locked. Sheet metal guards are placed around the die parting close the die and metal screens are hung between machines. extra guard ar- ranged swing into place the dies close further safeguard against any chance metal reaching the op- face should occur. All furnaces are insulated and have closed hoods connected exhaust system which draws off fumes and helps keep the room cool. This ap- plies also the Schultz machine, one which used, and the two Kip- casters which are employed for mak- ing some castings suited production machine are hydraulically operated from built-in Oilgear unit, and the Kipeasters, which run about 400 450 shots hour, are air operated opening, closing and locking dies, hand wheel being used actuate ejec- tor pins. The Schultz machine takes the same dies used the Yale machines and operates about the same speed. the dies for the for casting the two halves four taneously. The gates eight castings are shown the fore- ground, one the hobs for forming parts the cavities and removable plug such hobbed and serted the die. Dark T-shaped plugs (near cen- ter) are remov- able and make possible cast parts for eight- een different key changes the same die re- moving serting other set eight side cores form pin holes used bling the halves the padlock. ° breaking castings from gate eight the sprue held tube nearly hid- den this view. the castings are broken off, they drop into the chutes and are thus sorted into tote boxes. Kipeasters are the same size and, being small, are easily handled and quickly changed. Operators use tongs remove gates castings from the dies and then lay the gates tote boxes, using care avoid marring the the castings are all small and nearly all thin section, they cool rapidly. Tote hoxes are wheeled adjacent posi- tions the casting room where about dozen power presses are set for trimming from gates and for rough cleaning flash from castings. Many castings are broken from gates hand, however, especially where flash — er 4 “4 \ light where subsequent machin- ing, which the flash cut away, required anyway. Motion time analyses made many trimming ing-off operations and set-ups which facilitate this work are used. one example, illustrated, gates are set with the sprue tubu- lar support around which are placed chutes, usually one for each casting the gate, with the chute opening directly below the castings. the latter are broken gloved hands, the castings fall through the respective chutes into separate tote boxes below, automatically sorting the castings for subsequent operations. Certain castings are pushed through shaving dies punch presses. Many these set-ups are such that two castings time are placed the die, one with each the hands, the latter then being free press the two tripping levers the press. least one instance, the gates coming from one combination die are delivered power press which chute set catch each cast- ing the press breaks from the gate, again giving rapid and automatic sorting. = 36—THE IRON AGE, July 1938 the battery Yale Towne die-casting machines shown with die open. Ejection the gate castings, one which the operator holding, done the lever his right hand. Shields are placed all around the die parting. ° ° ° SPECIALLY designed electric spot welder combination with long, vertical side-assembly jigs being used the Chicago plant the Standard Mfg. Co. the assembly side sheets refrigerator and box cars the vertical position after the side frames have been fitted and arc welded. All welded construc- tion results light weight, low maintenance cost, smooth outer body surface and adequate strength. cars made thus far the saving approximately tons per car dead weight, resulting average saving 54,000 ton-miles per car per year. Accu- rate timing the current flow the welds assured General Electric Thyratron controls, which also cause energization the magnetic contactor precisely the same point each time the voltage wave. 0 ig tu HEN first developed, the hard- facing process was purely maintenance operation gated the welding department. Worn parts were sent that department surfaced with wear-resistant al- loy, and, when renovated, turned service. the savings made possible hard-facing became more generally known, many plants began process new parts prior their initial use. Then, more and more maintenance departments value, the demand grew until now manufacturers’ specifications call for ° ° ° surfaces most valves for high tem- high pres- such this throttling valve disk, are furnished hard- faced the valve Spe- cial jigs facilitate the Hard-Facing Problems Today PENDRELL Haynes Stellite Co., Los Angeles the use hard-faced parts many types equipment. Hand-in-hand with this growth have been the improvements methods and equipment for the correct, efficient ap- plication hard-facing materials. Such improvements benefited manu- facturers hard-facing equipment and their customers equally, for with part manufacture production basis, overall time and costs are less, and results service are more uni- form than when occasional parts were hard-faced. Good results from production hard- facing methods have been facilitated large degree recent advances the knowledge the effects of, and the precautions observed during, the application the welding flame parts various sizes and shapes. other shop operations, each part protected with alloy surfaces must studied individually and the best method for each worked out ac- cordingly. While the purpose all hard-facing operations the same, all seeking obtain maximum wear resistance the surface maxi- mum toughness the base metal THE IRON AGE, July 1938—37 2—The use rotating table jig speeds the hard-facing undercutter bits for coal cutting machines. under the facing, differences sizes, shapes, materials, ments, and desired production speeds will necessitate variations the de- tails the procedure. Types Operations Generally speaking, hard-facing op- erations can subdivided into three classes: manufacturing new parts, production maintenance, and intermit- tent job work. The hard-facing parts for installation new machin- ery and equipment probably the most highly developed and specialized class operation. Production mainte- nance, plants whose shops maintain their own equipment and keep one several operators full time the same type surfacing work, close sec- ond. Intermittent job work, the hard- facing individual parts unspeci- fied intervals—jobs which can done either the plant welding department outside job shop—is the class work where procedures standardized practices depend largely upon backed recommendations and gen- eral knowledge welding procedures. Facing New Parts Parts falling into the classification designated manufacturing new 38—THE IRON AGE, July 21, 1938 parts cover variety fields. Typical examples which illustrate the diversity such hard-faced products are gates, disks, needles and the seating surfaces valves for high-temperature, high- pressure steam, gas, air, oil, exhaust valves and vale seat inserts for internal combustion engines; shaft sleeves and impellers for heavy-duty pumps; oil well drilling bits; type conveyor screw sewage comminuter cutting plates, and even feet. outstanding application hard- facing materials now production basis the welding non-ferrous cobalt-chromium-tungsten steam valve seating surfaces. While some valve manufacturing plants this operation has been standard for high-pressure, high-temperature work for over five years, shown Fig. recent specifications calling for hard- faced valves for service pressures low 150 per sq. in. have re- newed efforts speed the operation and reduce valve cost still further. Exhaust valve seat inserts for in- ternal combustion engines, such those for service buses trucks and heavy-duty gas Diesel powered stationary engines, are hard-faced be- fore installation the engine. After rough machining, during which the seating surface grooved provide substantial support for the alloy de- posit, the insert rings are preheated, They are then placed the chuck motor-driven jig while the operator applies the hard-facing alloy the oxy-acetylene process. exception- ally smooth deposit obtained, requir- ing minimum finishing. After slowly cooling, they are ready for finish machining and grinding. Oil Well Bits Rotary drilling and coring bits for oil wells are now invariably hard-set and hard-faced before use. some plants doing this work, all forging, preheating, welding, finishing, and heat-treating processes worked out high degree preci- sion. Correct forging and pre-heating conditions have been determined for each steel analysis which bits are made. Spacing, hard-setting, and bonding the cast tungsten carbide inserts the bit have all been very exhaustively studied with regard the effects each when the bit service. Inserts are now spaced along the cutting edge that when the areas between them are worn, project like teeth fingers, penetrat- ing the formation rapidly. Inserts are also placed such way along the reaming edges that bits remain out-to- gage even after drilling many hun- dreds feet. When the bit has been completely hard-set with tungsten car- bide inserts, coated all over with crushed tungsten carbide particles, further protection. Homemade fixtures can speed the hard-facing, they are adjustable allow the area beiag welded level. When one face the bit has been hard-set and hard-faced, the bit can quickly turned over. Carbon blocks are frequently used limit the extent the hard materials and there- shape the bit edges almost exactly. Much finishing time saved and lit- tle none the hard alloy wasted. addition, gaging members are usual- -ly provided such jigs aid the welding operator keeping the blades concentric and true with the threaded box pin, that the bits will run smoothly and drill straight holes. Hard-set and hard-faced manner, single bits have drilled from 2000 2500 ft. the East Texas and South Texas fields. Recent perform- ance records these bits can now credited very considerably the use proper practices hard-setting and hard-facing which have taken years develop. Fixtures, templets, carbon molds and other aids now assist be 7 i cn ev wi Ste wt re; we la 7 ) By making the bit dressing operation et- ficient and economical. Maintenance Operation many cases, parts faced maintenance operation the plant where the equipment used. these cases, too, quantity produc- tion, high speed methods are used maximum efficiency. steel plants, rolling mill guides are one the outstanding examples this type work. Many mills hard-face new guides before putting them service. The hard-facing alloy applied groove the face the guide, located that the alloy surface receives the brunt abrasion from the steel pass- ing over the guide. the cobalt- chromium-tungsten alloy used for this purpose has exceptionally low friction, and remains hard even when heated red hot, wear and the constant need for regrinding are cut When the hard-faced guides are worn, they are reground the same steel guides, but when they are finally out point beyond economical they are returned the Welding shop and hard-faced again. method keeping guides con- dition found most economical. Coke pusher shoes, even latch bars, and carbon scrapers are regular maintenance opera- tion many coke oven plants. The hard-facing coke pusher shoes most economical when thick laver alloy, about in., applied all over the bottom the shoe. the metallic are process, beads alloy are laid parallel each other across the shoe, forming solid layer in. deep. Another layer then ap- plied longitudinally, covering the first completely, until the desired depth deposit reached. With relatively smooth deposit, quent finishing necessary, and the shoes can used immediately. Ordi- nary steel shoes wear rapidly because the abrasion high temperatures this service, but shoes hard-faced this method have long life. additional factor favor the hard- faced shoes that the brick furnace floor does not show much wear when ordinary steel shoe used. Crane tong points for rasing hot ingots from the soaking pits bloom- Rapid hard facing plowshares accom- plished with the aid fixture and copper plate clamped the nose. Groove for facing qj edge grind off ing mills are also usually hard-faced the maintenance department. New tong bits are machined down and the points are rebuilt with hard-facing al- loy means the oxy-acetylene process. Regularly hard-facing these points some plants has reduced the tong bit inventory per cent. ad- dition, because the hard-faced points steel points, the cranes can used with very few halts for point replace- ments. Hard-facing undercutter bits for coal cutting machines operation coal mines where the coal reasonably clean and free from boulders “niggerheads.” Thousands bits are normally used every week, and keep them sharp and insure fast cutting, one man must often de- vote his full time the hard-facing. Although just drop hard-facing alloy flowed onto each bit—as many 3000 4500 being hard-faced with single pound alloy certain mines—the large number bits tipped necessitates the use jig hold the bits position and minimize handling time. After considerable ex- perimentation, rotating table jigs have been adopted some mines, Fig. for the bits can spaced the jigs and the jigs rotated that while one bit being tipped, the one adjacent being slowly but ade- quately preheated the welding the same time, the proximity the bit just faced the source heat assures moderate and even cooling. With suitable jig, (CONTINUED PAGE 45) Groove for welding Block for roll scraper blade. (Upper left) The steel strip grooved preparaticn for hard-facing; (right) arrangement for bending blade during hard- facing operation; and (lower left) completed blade, showing method machining and grinding and the final appearance the sharpened edge. THE IRON AGE, July > ES / | low one for running. a.c. induction motor, the most noteworthy motor development 1938 thus Other motors are high torque types, splash proof, explosion-proof and pivoted base models; also motor with herringbone rotor de- trollers, large size circuit breakers, variety push button stations for special services and number electrical auxiliaries are de- scribed. Glass fiber tapes are coming into use for heavy duty motor windings. num- ber new industrial lighting Wagner high torque, dou- ble capacitor motor has high capacitance for starting and 40—THE IRON AGE, July 21, 1938 LEFT ROCKER WHEEL- ER’S new polyspeed a.c. motor shown ap- plied shaper drive. The speed regulator unit the right, convenient the operator. LEFT TATOR secondary the speed control- ler for Crocker-Wheeler polyspeed motor. The sec- ondary windings are con- nected brushes the motor commutator. YPE polyphase induction motors, range from 15,000 hp.. made the Burke Electric Co., Erie, Pa., now come pivoted base mounting. The pivot mounted bronze bush- ings and adjustment required, but the motor has slotted feet for belt justment time installation. The motor automatically keeps the belt ten- sion proportion the load. Pivoted type motors are ball bearing equipped and like other type models have stator frames welded steel. sign. Motor starting con- fixtures NEW approach the problem variable speed a.c. motors found the new polyspeed mo- tors recently announced Crocker- Wheeler Electric Mfg. Co., Ampere, Fully continuous speed regula- tion from 1800 r.p.m. can ob- tained three-phase induction mo- tor without rheostat losses. The stator winding connected directly the three-phase power line adjustment The rotor core has single winding similar d.c. wind- ing and connected commutator with fixed brushes. Speed control had varying the voltage across the brushes means an_ induction regulator. The rotor comes such speed that the voltage induced the revolving magnetic field created the field windings just slightly AST iron construction with system prevent entrance water falling particles and improved ventilation system are found the new line splash- proof motors made Diehl Mfg. Co., divi- sion Singer Mfg. Co., Elizabethport, Sealed ball bearings are used. Made all sizes and ratings. pri — Controllers and Industrial Lighting Equipment higher than the bucking voltage ap- plied the motor brushes. re- versing the voltage applied the brushes, aiding voltage applied and speeds per cent higher than synchronous are possible. (Synchron- ous speed, 1200 r.p.m.). The motor operates full field develops full torque over the entire speed range. The efficiency tively high all speeds. The speed regulator consists two single-phase induction type voltage regulators placed one frame, with the two rotors common shaft. The primary windings the rotors are connected the power source and the secondary stator windings nected the brushes. The secondary depends upon the relative posi- tion the primary When the axis are right angles, for example, voltage in- duced; when they are coincident, maxi- mum voltage induced. High Torque Motor their line single-phase mo- tors, Wagner Electric Corp., St. Louis, has added high torque, double RIGHT CLOSED system forced ventilation incorporating su