The Iron Age 1938-09-01: Vol 142 Iss 9

asked addi- Taus- Buren Field, for Bou- wea- has North p for noved mu- dis- ),000. eenth Wil- ining com- inits, andle Cost gton, Don- and time new FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham LEROY ALLISON Roy Newark, N. J. St. Louis TURNER, JR. Buffalo Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th St. New York, N. Y. OFFICERS AND DIRECTORS A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE EVERIT TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- $8.50; Foreign, $12.00 year. Single copy, 25 cents. Cable Address, ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg., 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. Bobinson, 428 Park Bldg., Pittsburgh D. C. Warren, P. O. Box 81, Hartford, Conn Cont SEPTEMBER 1938 Not Fellow Worker Surface Finishing Method Lighter Pullman Box Cars Annealing Wire Radiant Tube Furnace Rotary Furnace Produces High Grade Progress Equipment for Finishing Metals New 44-In. Mill Industrial Tractors and Tractor Trains Automotive Industry Washington News THE NEWS BRIEF Rate Activity Capital Goods Weekly Ingot Operating Rate Plant Expansion and Equipment Buying Just Between Two Products Advertised Index Advertisers Copyright 1938 Chilton Company (Inc.) 105 130 plans drow ),000. Fed- ilsom 1661 lanes one com- edule set otor- Sept. main stern ‘alls, Los and sta- new from cuit, 100 part- for nent : —— « Shipped With the Steel Ryerson Certified Alloy Steels are not only shipped quickly, but complete information arrives with the bars, including chemical and physical properties and record heat treatment results. this way, the heat treater knows what each alloy and exactly how treat for the best possible results. This unique alloy plan,never before attempted any steel service company, the outstanding feature Ryerson Certified Steels. Ryerson Certified Carbon Steels, Tool Steels and Stainless Steels are ordered exacting specifications and pass rigid inspection before they are accepted for Ryerson stock. For high, uniform quality, specify Ryerson Certified Steels. They cost more and quick shipment assured. JOSEPH RYERSON SON, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City Alloy Steels Heat Treated Alloy Steel Bars Stainless Steel Cold Finished Shafting Screw Stock Extra Wide Cold Finished Beams and Heavy Structurals Channels, Angles, Tees and Zees Hot Rolled Bars—Hoops and Bands Rails, Splices, Spikes, Bolts, Plates—Sheets Strip Steel, Wire, etc. Boiler Tubes and Fittings Welding Rod—Mechanical Tubing Rivets, Bolts, Nuts, Washers, Reinforcing Bars Babbitt Metal and Solder — 4 ~ 7 | THE IRON AGE ... ESTABLISHED 1855 SEPTEMBER 1938 Vol. 142, No. Not Fellow orker OONER later the American steel workers must learn some the bitter truths about their eloquent friends, the politicians. Even William Green and John Lewis, intent kicking and gouging each other around the labor ring under the rules the Wagner Labor Rela- tions Act, have their moments disillusionment. Only recently the President named the five men considered most responsible for establishment the Social Security Act and Mr. Lewis and Mr. Green were not the list. All the five men are politicians, able fellows who have done something are expected something for the benefit their masters Washington. Yet none these five are labor leaders the accepted sense the term, and public acknowledgment that the five headed the list those going bat for this legis- lation must have left Mr. Green and Mr. Lewis considerably annoyed. They, too, have labored the vineyard. the New Deal considers labor union leaders necessary evils scraped off into the nearest ditch when opportunity arises, now the time for Mr. Green and Mr. Lewis thinking about it. common with all American steel workers, with workers all industries, these two labor chieftains might also thinking about Government costs, the politician's They should likewise warning their followers, just employers should tell- ing their employees, that taxes are steadily draining dry the pools from which wages come. For the first half 1938, this drainage amounted million dollars for the steel industry alone. Federal, state and local taxes paid steel manufacturers the first half this year were equivalent full month's pay for 327,000 employees. For the full year the steel industry will have paid the Government the equivalent two wages for third million men. Every employer the country would well translate his tax bill into wages and tell his employees just how many dollars might have been paid them wages this year had not been for the tax collector's visit. Every labor leader, starting with Messrs. Green and Lewis, should some figuring for his union members the blighting effect industry's 1938 tax bill the pay envelope before reaches the worker's hand. Surely the Tax Collector not Fellow é pal id | 7 7 q als etc. ubing - F The Conception, Development, For Entirely New Surface WILLIAM SHERMAN Detroit Editor, The Age HEN special finishing opera- tions were first opened broad new achievement precision manufacture. Recent developments the automo- tive field have given this industry the means for developing finishes almost the point perfection, with con- trol possible within fraction millionth inch. This means producing “optical flats” metal, the equivalent gage block finish production parts few seconds, has been made avail- able through three years research special group men the Chrysler Corp. They have developed new mechanical equipment using rela- tively coarse stick-type stones which few seconds remove all measur- able surface defects from metal parts. Combining its technique many the methods common simple honing lapping, the new process departs from these many fundamentals and has implications broad and deep changes come manu- facture. Coincidental with this independent research organization working with Chrysler produced for the first time commercial device which could measure variations the smoothest metal surface speeds thousand times greater than was pos- sible with previous instruments. Wallace, president the Chrys- ler Sales Corp., division Chrysler Corp. Having supervised its develop- ment over period three years, defined as: “An extremely fine surface finish produced upon flat, internal, exter- 18—THE IRON AGE, September 1938 nal, round, concave, convex, and other types surface combi- nation short motions, light abra- sive pressures, slow abrasive cutting speeds, hard abrasive stones and lubricant proper viscosity that eliminates the scratches and surface defects created previous mechan- without creating scratches defects.” Implied similarity honing lap- ping incidental and unavoidable. Actually, the new process only rem- iniscent the other two. The differ- ence between Superfinish and other shown Fig. which indicates why the process merits its new name and calls for entirely new engineering outlook the subject fine surfaces. The process produces finish with characteristics quite different from simple honing lapping. has af- fected the processing schedule for many parts, frequently reducing man- ufacturing costs. Because improves lubrication and tends wear, possible that will change features design many precision devices such the automobile engine when applied more generally their manufacture, and when all the advantages have been demon- raised the demand that surfaces specified with finish within defi- nite range (as dimensions are stated with tolerances) or, alternative, that surfaces rated (as gages are classified degree accuracy). Applied Many Parts Tangible results are seen today roller bearing races, crankshaft main bearings and pin bearings, camshaft bearings and cam contours, bearing journals, cylinder bores, pistons, pis- ton pins, valve tappet heads, valve stems, brake drums and shoes. Fur- ther applications spring shackles, king-pin bearings and steering gear parts are pending the automotive field. Also being studied the appli- cation Superfinish aircraft valve rocker arm bearings, variable pitch propeller mechanism, control and landing wheel bearings. The process also can used for variety other mechanical parts, ranging size from bearings mill and steel mill rolls. obvious that one the im- portant aspects Superfinish the fact that easily applied merous geometric shapes, including flats, tapered holes, concave and con- vex surfaces, round shapes (external, well bores) and cam profiles. Even for “shoulder” work, Superfin- ish can applied insure the re- | q — 7 7 | | 4 Equipment and Measuring Methods Finishing Method —Superfinish Chrysler Corp., produc- tion research engineering department, with the editors The Age here presenting comprehen- sive story new technique surface finish, called Superfin- Superfinish not only involves entirely new shop technique and the design many ma- chines, but might said entail new shop and engineer- ing philosophy metal finish- ing. After three years exten- sive research, the details these studies are here discussed length and illustrated original test data. President, Chrysler Sales Division, Chrysler Corp. moval scratches which might be- come incipient fatigue cracks. How Study Started The attention group Chrys- ler manufacturing experts rected this subject three years ago when Mr. Wallace discovered that harmful brinell marks were made the rollers roller bearing races rear axles cars shipped transconti- nentally rail. first complicated explanations were offered for these indentations which produced noise and eventual bearing breakdown. Among the explanations were that corrosion, the effects electrolysis, etc. However, Mr. demon- that lapping would remove the infinitely thin layer grinding “fuzz” which, had discovered, was what really had been indented brinelled from the pounding effect produced the railroad cars the rails. The base metal was unaffected. The investigation that was launched then eventually brought about com- plete change the manufacturers’ methods finishing the bearing races. the course solving the problem, the automotive men collaborated with Timken Roller Bearing Co. and had Krueger Co., Detroit, build machines incorporating the principles Superfinish. The original machine, Fig. had four heads which operated 500-grit disk stones inside the bear- ing races with rotating, oscillating movement the presence con- stant flow cutting fluid. With speed 150 r.p.m. and very light pressures the work, the time re- quired produce satisfactory finish was less than min. per bearing race. Resu!ts were outstanding that the Chrysler Corp. proceeded investi- gate surface finishing large num- ber automotive parts. The success this more ambitious program for the development better finishes can measured glance the chart, Fig. Before the start the Superfinish program, production parts were given what observer would call conven- tional processing, with usual results. Camshaft and crankshaft bearings, valve stems, cylinder block bores and tappet heads, all were smooth within in. in.). The crankshaft, which was given precedence the development work, showed the most immediate and marked improvement surface finish. 100 per cent im- provement the crankshaft has been registered since the start the pro- gram. was demonstrated that lapping crankshaft bearing means paper cloth charged with abrasive, there natural tendency for the tape follow and conform all the surface irregularities presented it. While this method may produce bright, glossy bearing surface (caused light reflected from scratches), im- partial laboratory evidence disclosed the true condition. Hence was de- cided make use fixed abrasive because held the only promise removing surface irregularities and bringing the surface base metal. Using lathe and simple test appara- tus, basic method for finishing crankshaft pin bearings was devel- oped. The crankshaft Superfinisher now used production shown Figs. and 4-A. hit-or-miss tactics entered the THE IRON AGE, September 7 tive itch arts per im- the nu- ing on- nal, les. fin- re- SUPERFINISH COMPARED WITH OTHER TYPES FINISH Diagram Scratch finish inches inches Finish 0.00005 0.000035 0.0002 Pitch 0.000005 0.0005 0.00001 0,0000005 finish 0.00001 20—THE IRON AGE, September Depth surface ductility, 0.00001 0.0001 0.002 0.1 0.00005 0.020 0.00001 ABOVE chart compares Superfinish with other types surface finish produced metal working tools terms depth scratches and their pitch. Su- perfinish has scratch pitch since the scratches are extremely light and irregularly spaced. LEFT 2—The first Superfinisher was built remove the grind- ing from the inside roller bearing races prevent brinell- ing the static condition. pitch, speed, inches |change, inches per min.| inches Depth 200 0.002 8000 1000 0.003 Work urnished Ball 0.0001 400 0.001 100 0.0001 Work Lapped 0.001 100 iner- — None evolves RIGHT 3—Yearly improvement surface smoothness typical automobile parts since the start the program August, 1935. determination the proper combina- tions pre-finish operations, stone selection, speeds motions for Super- finish. shown Fig. series crankshaft pins (four groups six) served material for one test. Each shaft initially was rough and finish ground with different sets stones. shown near the top the chart, pins not Superfinished showed smoothness 35, 21, and micro-in., respectively. Then, indicated the lower part the chart, the pins were Superfinished, using different sets stones each bearing determine the most effec- tive ones. The chart shows that No. bear- invariably turned out best. The most satisfactory combination that indi- cated Group where the coarse stone used for Superfinish after rough grinding with Norton 46-Q-4A and finish grinding with Norton 70- N-5 stone. this case, the prelimi- proved approximately micro-in. for the final finish. course, the development such precision finishing equipment could RIGHT the crankshaft Super- finisher, each stone holder oscillated sideways through eccentric driven individual Hi- cycle electric motors. Drive units and stone holders are supported master crankshaft which ro- tates synchronism with the work, Oscillation 450 per min. LEFT Detail the stone hold- ers for Superfinish- ing Micro-inches, millionths THE IRON AGE, September Brake drum 0.022 feea Brake drum 0005 feed Aug Aug Aua 1935 1936 1937 1938 wo Superfinished not have proceeded without yard- stick which would give means comparing surface roughness. Once finishes could compared exactly, charted and controlled. that time Dr. Abbott the Physicists Research Co., Ann Arbor, Mich., was probing into the subject with device called the Profilograph Pro- filometer. Only two laboratory models were existence, but Mr. Wallace encouraged the development more usable apparatus for the shop. Development the Profilometer For general use automotive plant for the measurement surface defects, the equipment must needs accurate, inexpensive, portable, and easily used production and large small parts, whether crowned, concave convex. Dr. Abbott proceeded with the develop- ment portable instrument shown Fig. with elements shown Fig. 6-A. The tracer point shown the diagram diamond tipped with 60-deg. angle and 0.0005-in. radius. This sharp enough bottom the principal irregularities the surface being measured. The diamond point mounted duralumin tube sup- ported light springs. How the movements the pointer are trans- lated into electrical voltages ex- plained the caption. the portable, commercial model, the meter will average the surface roughness the tracer passed over the object. flexible 22—THE IRON AGE, September 1938 4 Bay State 500-H Bay Norton Norton Bay State Finish Finish Grind-Norton-80-L-5 From these Profilometer readings shaft pin bearings shafts, the most able stone for rough and finish grinding ing was determined. No. bearing group shows the best performance. Its final finish less than tool ing tion the Profi devic thous matic regu to re mate also scrat ities. mere base leng then sona the a se men sma used pro? (0.0 As Superfinished ° ° ° | S wo = ~ S tool which will permit readings vary- ing from less than in. 0.001 range 1:1000. The magnifica- tion far better than possible with the best microscopic equipment. The Profilometer essentially high speed device capable making traces one thousand times rapidly any pre- vious instrument. permits auto- matically taking continuous running average the height surface ir- regularities, and the scale calibrated read directly micro-inches. Esti- mates can made low tenth millionth. The instrument will also indicate the presence individual scratches and other unusual irregular- ities. Accepted methods testing surface smoothness vary all the way from mere visual observation estimations based measurement the wave lengths light and even evaluation the coefficient friction. All them rely great degree per- sonal opinion estimation. Even the use light wave lengths, there serious optical instru- ment can form images object smaller than the wave length light used. For ordinary light this ap- proximately millionths inch (0.000020 in.), has been discussed LEFT olicy the part the Chrysler Corp. and its leading executive, Keller, modern industry has been given access Superfinish, new process fostered Chrysler after in- tensive research. Applications now effect near realization range from plows aircraft, from automobile engine tappets 50-ton steel mill rolls. Today the most talked mechan- ical development having been viewed approxi- mately 400 production and en- gineering executives, including many from abroad. Even was being demonstrated these visitors Chrysler's Jef- ferson Avenue plant, new phases the development were un- folding. The latest these, and the first complete story Su- erfinish, are revealed this IRON AGE series articles. necring, March, very the portable Profilometer checking the smoothness automobile engine cylinder bores. Average roughness millionths inch can read directly the instrument scale the right. BELOW Diagram elements the Profilometer. The tracer point stem carries coil its upper end and vibrates the magnetic field, electrical current generated, the voltage which can amplified suit- able means any desired value. The instrument shown hooked cathode ray oscillograph with means for obtaining photographic record moving film. the commercial models, galvanometer substituted for the oscillograph and has enough dampening average out the irregularities the surface. suitable calibration will indicate the average depth scratches directly micro-inches. Special Tracer unit amplifier Tracer unit Special Special circuits amplifier Mofor driven camera whose width from 400 times the height. what calls roughness, the width “pitch” scratches from 150 800 times the height, but these instances the height does not exceed micro- in. Hence, these heights cannot observed optical means. While microscope with suitable illumination valuable for obtaining data the plan view surfaces, the height irregularities smooth surfaces. the work undertaken Chrysler, the heights surface de- fects were considerably more im- portance than the plan dimensions the scratches irregularities. (To CONTINUED) Japanese Take Over Chinese Steel Firm CCORDING report the Department Commerce, the Central China Steel Corp. (capitalized subsidiary the Central China Promotion Co. The Nakayama Steel Works Tientsin also reported expanding its machine tool plant. Japanese press reports that all Chinese iron and steel manu- facturing works throughout Japanese occupied areas have been transferred the Army the ownership major Japanese company which ex- pected expand those enterprises meet the entire Japanese demand. The Kungchin Iron Works private Chinese concern) located the Yangtzepoo area, Shanghai, stated have been taken over Japanese interests and now being operated the “Asiatic Works No. Fac- tory” and turning out steel nets. The Hwa Shang Iron Works merly Chinese private concern) now engaged the me!ting scrap iron collected from various areas after occupation Japanese. Twenty- six tons “iron” melted every day and, according reports, being sent Japan. Stanley Works Trying Find Oldest Unishear Use TANLEY ELECTRIC TOOL DI- VISION, STANLEY WORKS, New Britain, Conn., has launched contest find out who owns the oldest “Mighty Midget” Unishear still use. The winning company, shop person will receive new “Mighty Midget.” The contest opens Sept. run until Oct. 31, this year. THE IRON AGE, September 1938—23 ter nk- nk- sh- Flux = bj Aff, A Ty Pullman Five Tons. ighter ROBERT BINGHAM Western Editor, The Age several the passenger car field, the Pull- man-Standard Car Mfg. Co., has apparently scored again with its new welded light-weight freight cars. Constructed mostly low-alloy steel, this car nearly five tons lighter than the standard A.A.R. car equal size and capacity, and thus accommodates five tional pay load. pact tests the Pullman lightweight box car and the A.A.R. standard box car revealed that stresses, pro- portion the point the ma- terial, were general lower the Pullman car than the Spot welding posts side sheets. 24—THE IRON AGE, September 1938 practically all speeds The overall results the tests show that the Pullman car and the A.A.R. car are both sound structures.” Construction entails the use three distinct methods: Spot welding, arc welding and riveting. The resistance spot welding method used one which the parts are overlapped and gripped between two electrode points through which heavy current passed and pressure applied make the weld single spot. Based upon total length seams, spot welding comprises per cent the entire op- eration, 2601 ft. being fastened to- gether this manner out total 3721 ft. seams. The tempera- ture, timing and pressure varies ac- cording the type, thickness and number layers material. The existing equipment the spot welding department able turn out roofs and sides hourly. Plans permit expansion the pres- ent layout double this capacity the future. All spot welding opera- tions are quartered new building with floor area about 140 ft. 220 ft. With the exception the roof appli- cation the steel body, all spot-weld- ing work concentrated this one building. Spot welding two non-indexing automatic double- head kva., two indexing automatic single head 100 kva., four stationary spot welders kva., nine portable tools 100 kva., and portable tools, kva. The non-indexing machines are used for spot welding the side shee chin bly rein the lane elec ing desi feat The side ° ° side for doo etc. the coa and | size arc afte sch ity sheet assembly and the sheet as- sembly. The indexing automatic ma- chines are for the door sheet assem- bly and the door post assembly. The the side posts and other miscel- sub-assembly work are welded the stationary spot welders. The electronic principle timing used most the machines with air tim- ing the balance. The portable tools were especially feature sub and final assembly. These are used apply the side plate, side sill, post connections, etc., the sides. Other portables are also used for applying the roof the car and for the final assembly the side doors. Each day test spot weld specimen made each machine and tested insure correct timing, temperature, etc. addition, inspectors sound each button every bench assembly guarantee continuous quality the weld. welding, which comprises 1030 ft. seams, 27.7 per cent the total the shielded arc type which coated electrodes are used. The type and size rod depend position, size weld and kind material. The arc welding inspected during and after welding experienced welders who have been trained inspectors. Each are welding operator has been schooled for his particular production job and has passed established set tests. Every bench assembly with either method welding made spe- cial jig insure uniform accuracy. The jigs for are all con- structed permit flat welding, elimi- nating the majority horizontal, ver- tical and overhead welds. Close super- vision, continued inspection and daily testing welds carried all The remainder the operations, 2.3 per cent, consist riveting, which employed along the corner post seam for the final application the ends the car and the side sills for the final application the sides the underframe. present, riveting ap- pears more advantageous than either method welding for these particular joints, according the com- thorough check welding and tiveting made inspectors the position the steel erection track, This new car has nominal capac- ity tons and interior revenue = Roof sections being spot welded special machine. THE IRON AGE, September are 4 ‘ ~*~ Side spot welding machine operation. @ Special jigs and portable spot welders used fabricating complete sides. wide and ft. in. high. The ratio maximum revenue load weight the rails 78.9 per cent compared with 73.7 per cent for the A.A.R. car. Side, roof, door and end sheets, end plate, side plate, and side sills are con- structed high-tensile low-alloy steel. The center sills are made high car- bon open hearth steel with minimum vield point 36,000 Wheels are chilled tread, 695 light weight de- sign, recommended the Association Chilled Car Wheel Manufacturers and approved the A.A.R. The side sheets are automatically spot welded together with 176 spots two rows spaced every in. vertically, staggered with in. be- tween rows. Roof sheets are welded automatically two rows spots staggered, spaced in. with in. be- tween rows spots, total 200 spots being made. Welding current volts, 5000 6000 amp. and pressure ranges from 700 4000 Ib. depending the thick- ness the material, with the average running about 1200 Ib. strength test this particular job revealed that in. spot ten- in. rivet. Following the impact tests, close inspection some 14,000 spot welds the Pullman car showed indication weakness failure. British Steel Output Lowest Years ONDON (By Mail).—The British Iron and Steel Federation an- nounces that United Kingdom produc- tion steel ingots amounted 683,200 tons July. This the lowest monthly total for three and one-half years and compares with 776,100 tons June, 1,059,200 tons July, 1937, and the record figure Completed car, all welded, except for corner rivets, high tensile, low alloy steel. 26—THE IRON AGE, September 1938 1,178,300 tons reached Novem- ber last. Pig iron output amounted 507,800 tons, against 541,500 tons June and 729,300 tons July last year. This included 120,500 tons hematite, 266,100 tons basic, 98,500 tons foundry, and 11,400 tons forge pig iron. There were furnaces blast the end July compared with the end June, furnaces having ceased operation during the month and four having resumed production. While steady supply Govern- ment work can relied some sections the trade, considered that the general domestic demand unlikely provide much work view consumers’ reluctance place or- ders before the expected price reduc- tions the end the year. Hence hopes are mainly centered ma- terial expansion export business. this connection, the improvement watched with interest.” said that the British exporters’ chances ob- taining greater share foreign business are hampered the preva- lence price-cutting, although the leading American exporters are operating with the British far lies their power. Leading Continental European centers are confident expansion busi- stated that large proportion the inquiry for iron and steel export account. Competition severely felt, however, and the question sending delegation Sweden with view stopping the increasing price-cut- ting from that quarter under dis- cussion. ty) P ditional wire annealing equipment, the Wilson Steel Wire Co. had the thought mind obtaining unit that would many different jobs could possibly done one type furnace. manufacturers many kinds wire and wire products, the company’s demand for annealed wire presented many problems due the variation products. considering the pu.chase ad- IG. this general view the square bell type annealing furnace with hor- izontal tubes, how one man handles the entire installa- tion. The loading and unloading pits are the foreground. nnealing Wire Radiant ube Furnace ° GRASSELL President, Wilson Steel Wire Co. The furnace selected would re- quired deliver product with phys- ical properties maximum uniform- ity; also, should produce an- nealed wire which would and thereby reduce pickling cost; the quality the annealed wire should fully satisfactory the buyer; and naturally, economy operation, cost equipment and capacity were also primary importance. Our study possible furnaces final- narrowed down the gas-fired tube type bell furnace, and three individual variations this construction were investigated. Tube type bell covers have been widely used the sheet and strip industry for some time and have proved most satisfactory. How- ever, there are three general tube type furnaces: (1) Square bell type with vertical tubes, (2) rectangular bell THE IRON AGE, September ind his Ite, pig ast - ing ind me red Z type with horizontal tubes, and (3) square bell type with horizontal tubes. For the plant the third type was selected. this particular equip- ment, supplied Surface Combustion Corp., the gas fired into horizontal cast alloy tubes giving luminous flame which results uniform tem- perature distribution, low flue gas tem- perature and high efficiency. Fig. illustrates the general lay-out the equipment. building was practically constructed around the fur- nace, thus furnishing opportunity install cranes which are ideally suited handle the cover well the ma- terial. The equipment shown con- sists loading and unloading pit, the furnace heating cover, three inner covers, three bases, and the overhead The furnace takes charge four stacks coils loaded spindles, sev- The maximum outside diameter the coils in. and the wire may piled height in. Four loaded spindles in. inside diameter give net charge approximately 13,000 lb. The spindles are placed cast metal inner bases, which also may seen Fig. They are arranged about centrifugal recirculating fan, which has four discharge ducts, one leading the center each coil stack, the result being that heating and are expedited during op- eration forcing the air through 28—THE IRON AGE, September 1938 2—This auxiliary equipment installed beneath the furnace. Two the re- circulating fans are shown the right. the center each stack and pulling downward the fan intake the bottom the base. inner cover made in. fire box steel, having inside diameter ft. in., placed over the four spindles (one inner cover the farthest base and another posi- tion lowered over the stacks wire Fig. 1.) The inner cover sand sealed the bottom. The heating cover which moved from base base and placed over the inner cover weighs about tons. The general construction, burner ar- rangement, and flue gas collectors are shown Fig. The motor valve controlling the flow gas, the ex- hauster fan, which produces stab- ilized suction the tubes, and other appurtenances are all mounted the cover but cannot seen Fig. The equipment supplied with five thermocouples, two which run two-point recording controlling rometer while the remaining three run three-point recording pyrometer. the two leads the controlling in- strument, one installed the inside the heating cover, while the other inserted stack wire within the inner cover. The other three go- ing the recording pyrometer are placed various points throughout the charge itself. This arrangement gives accurate temperature data all times throughout the entire charge. Fig. shows the auxiliarv equip- ment installed beneath the furnace bases. the left the foreground are the gas booster and gas meter, and the rear the floor are the recirculating pump reservoir water tank. This water used for cooling the bearings the hot base fans. The piping where con- nected the nearest base fan can seen the right-hand side the picture. two-ton crane was installed with motor operated lift and travel, but manual racking mechanism for travel across the bridge was incorporated. This crane installation loaded spindles and high speed lift not shown the pic- ture. This was installed that one man could handle the complete job, for times necessary for him load and unload wire bundles weighing much 500 Ib. 15-ton telepher type monorail hoist was installed for handling the heating cover. Only the end the carrying rails can seem Fig. The 15-ton crane operated one man standing the controls, Fig. and this man can lower the hook, engage the lifting lug, lift the heating cover, move the next base position, and lower over the guide post without leaving his position (CONCLUDED PAGE 47) Stuerzelberg process for the production good, clean molten iron rotary furnace, using calcined pyrites (purple ores), left over after the elimination sulphuric acid, and either coke, pitcoal lignite fuel, has recently been described Hofmeister, Duisburg, Ger- many, the equipment being patented and made Demag Aktiengesell- schaft. This same unit has been conceived low-cost producer pig iron competition with the conventional blast Rotary Stuerzelberg Furnace Produces High Grade furnace using, course, equivalent grades ore and coke. widespread experiments have shown that the Stuerzelberg furnace cannot economically compete, production per furnace unit com- paratively small and consequently would handicapped too much overhead cost and amortization, compared with the blast furnace. However, the Stuerzelberg process said able better than hold its own with the blast furnace process those cases where small quantities iron are produced, owing limited marketing possibilities special conditions freight, where there coke suitable for the blast furnace process when the coke available too expensive, while pit- coal lignite are had. The reduction can done with nut coke gas coke and also just well with anthracite, charcoal pitcoal, the furnaces are heated with coal dust. The various stages the develop- ment the Stuerzelberg process were originally described Stahl eres aoe: Fic. mode operation the calcined pyrites plant Stuerzelberg. Coal dust bunker. Delivery air for coal dust. Hot air pipe. Regenerators. Combustion chamber. Inlet for secondary air. Slag box. Preheater. Filter plant. Burner. Fan for air combustion. Charging bucket for mixture ore, coal, and lime. Hot metal ladle. THE IRON AGE, September : ti J > Eisen, No. 1937, but the application zinciferous calcined pyrites came later, and may described The calcined pyrites contain ap- proximately per cent Fe, 0.02 8.20 Zn, 0.02 Cu, 0.40 Pb, 0.20 Mn, and 10.20 SiO,. The pyrites are roasted down beforehand sinter- ing plant sulphur content 0.1 per cent, then mixed with coke breeze and limestone certain proportion special charging devices. The mix- ture passed bunker and thence into preheater, which retort fur- nace preheated the waste gases from the rotary furnace. Sulphur need not eliminated beforehand from the calcined pyrites, because has been found that the special treatment the charge undergoes the rotary fur- nace produces iron with low sulphur content. The drying the mixture the preheater essential, otherwise the moisture that gets into the rotary fur- nace along with the mixture would destroy the dolomite be- fore the end preceding melt, the preheated mixture passed from the through funnel into bucket. This bucket carries the mixture rotary furnace, where charged. This entire cycle shown When charging, the rotary furnace tilted deg., and during the work- ing cycle the bottom opening the inclined rotary furnace closed cover prevent the mixture running out. The steel jacket the rotary furnace 12.5 ft. diameter and about ft. long. Toward the two ends the rotary furnace becomes coni- cal shape and has two rings which run four rollers, and these rollers are installed special equipment which makes possible for the rotary furnace tipped. The mixture ore, coal and lime put into the rotary furnace heated coal dust flame about 2730 deg. whereby pasty ferrous sili- cate envelops the sponge and protects this way from burning. The lime has the effect gradually the ferrous oxide from the ferrous silicate slag; the ferrous oxide then being reduced the carbon. more carbon added the charge than required for the reduction, the reduced iron absorbs carbon, melts and, consequence the rotating movement the furnace, detaches it- self from the slag. then can poured separately from the slag, Fiz. Although the slag the case the 30—THE IRON AGE, September 1938 Stuerzelberg process kept highly basic, out regard for the desul- phurization, and hence very viscous, yet the continuous turning over the charge results excellent desul- phurization, necessary, down 0.01 per cent. The carbon content too can changed according requirements recharging carbonizing agents. already mentioned, the vessel the rotary furnace heated coal dust portion the normal air combustion obtained from regener- ators temperature 750 930 2—Rotary furnace tilted for teeming. The preheater for the mixture ore, coal and lime may seen the background. deg. being brought higher pres- sure means special fan and used for delivering the coal dust. The waste gases the furnace, which have been augmented the oxygen expelled, the carbonic acid the lime and the zinc oxide formed, pass the rear the rotary furnace into very large slag and dust catcher where the main impurities, chiefly ash from the coal dust, are separated from the waste gases. The adjoining, spacious gas flue going the regenerators serves like purpose. order initiate the combustion the carbon monoxide the waste gases, second- ary air admitted the waste gases this gas flue. This combustion in- creases the temperature the waste gases 390 570 deg. The regenerators are packed with perforated brick. order able get rid the ash residues the coal dust, which, mixed with oxides, still deposit large quantities there, the arches the regererators and their covers are designed such way that accumulations dust can removed with the help special device. After the waste gases have left the regenerators, they pass into the pre- heater already described where they are used dry and heat the mixture ore, coal and lime for the next melt. The large number baffle plates the preheater also help lot sepa- rate the dust. After passing through exhaustor which serves produce the depression the entire furnace system, the waste gases pass into bag filter where the oxides are Even though portion the zinc oxides precipitates already the in- terposed apparatus, the bag filter that the main portion sepa- rated. also here that the purest oxides are separated and this yield, which finds ready market, im- portant asset the process. harm would done the bag filter the temperature were above below that necessary for the waste gas, special devices are provided the degree. The waste gases are evacuated rear the filter. The slag, which kept highly basic for desulphurizing the pig iron, can under certain circumstances used high-grade by-product for mak- ing cement fertilizing lime. The slag Stuerzelberg contains for in- Fe. contrast the process, frequently talked about present Europe, which iron ores with car- bon are reduced pasty state long rotary furnace and which the low carbon blooms produced, that are mixed with slag, have more less high sulphur contents and still have freed from the slag order melted down special furnace, the pig iron the case the Stuerzel- berg process produced molten state practically free from sulphur and completely separate from the slag and, when required, can cast direct for products iron foundries adding alloying agents. The Renn process continuous one, whereas the Stuer- zelberg process carried out in- dividual melts. The pig iron produced far the latter process said great demand from plants mak- ing alloy and special steels admixture for high-grade products, the iron supposed equiv- alent the best Swedish charcoal iron used for such purposes. h a Cc n 5 I n / giant alkali stripping systems paint completes the cycle finishing metals. Also included this review announcements the suppliers are new forms rubber and plastic tank linings, shot blast cleaners, polishing equipment, plating accessories, improved metallizing gun and variety spray guns for paint and lac- quer, together with respirator units for worker safety, also strip heaters for bake ovens. HAT believed the larg- est alkali stripping system was recently built Detroit Rex Products Co., 13005 Hillview Avenue, Detroit, for removing paint from rejected metal parts preparation for repainting. The system consists hot alkali strip tank 15,400-gal. ca- pacity, which the work immersed for min.; hot alkali sprays the overhead type; cold water sprays; and hot water rinsing tank 8000-gal. capacity which the work merged for min. There also mixing and preheating tank 1500- gal. content. All three tanks are heated steam coils. The tanks proper are welded plate and structural reinforce- ments. Approximate overall dimen- sions are: length, ft. in.; width, ft. in.; height, ft. in. Tank Liners NEW and improved rubber lining for tanks and other containers for plating and chemical service announced Collord, Inc., 7048 Lyndon Avenue, Detroit. The coalesced multiple plies latex rub- ber formulation gave the name Mul- ti-Ply S.R.L. The material “tai- lored” the tank single, seam- less, smooth finish, the whole being efficiently bonded the metal wood, according the maker. LAST-O-LINE thermoplastic tank lining possessing unusual Current Progress Equipment for Finishing Metals ° ° ° FRANK OLIVER Associate Editor, The lron Age chemicals and acids, according the maker, Heil Co., 3088 West 106th Street, Cleveland. Tests conducted standard bright nickel show contamination from this lining. resistant most commercial acids per cent concentration, with the exception chromic fluoric acids, and will resist weak or- ganic acids, well alkalis all concentrations and temperatures 212 deg. will resist a!cohol concentrations per cent. Plast- will not, however, resist con- stant mechanical abrasion. The Heil company also introduc- ing complete acid brick lined tanks for ° ° chrome plating, muriatic acid and hy- drofluoric acid pickling. Such brick linings offer greater resistance me- chanical abrasion, are good heat and electrical insulators and are practical- non-corrodible most acid solu- tions. Three types are made. Speedier Parkerizing Process ASTER processing time and low- operating temperatures are claimed for new Parkerizing proc- ess, recently announced the Parker Research Laboratories, stead the former min. proc- essing time the tank method, only min. now required. The new ARGE Detroit-Rex alkali stripping system, showing stripping tank left and hot water rinse tank right. The premixing tank behind the A-section raised platform. THE IRON AGE, September reacts 180 deg. instead 212 deg., formerly found necessary, lower heating cost. The improved liquid chemicals also develop less sludge the processing tank and produce finer grained, smoother coating. There less change part contour and minimum build-up fine threads. The shortened proc- essing time makes possible the use relatively smaller tanks. Cleaning Barrel SMALLER Tum-Blast has been added the line airless centrifugal blasting 32—THE IRON AGE, September units made the American Foundry Equipment Co., Mishawaka, Ind. The new model has load capacity cu. size. intended for plant having limited volume small pieces clean auxiliary unit handle light loads. principle operation similar the larger sizes, except that wear-resisting rubber conveyor used instead metal conveyor for tumbling the work. The machine ABOVE OLLORD, INC., has developed new method pro- ducing multiple ply seamless rubber lined tanks, said im- mune blisters and capable standing high temperatures. LEFT OODYEAR TIRE RUB- stalled its Akron plant 90-ton curing heater, with 17-ton door inside the shell, for vulcanizing Plio- weld installations various types pres- sure and storage tanks, railroad tank car shells. the Plioweld process, protective layer rubber applied the cemented metal surface. LEFT tank for pickling copper wire rod coils lined with 3/16 in. Tri- flex rubber—a com- bination hard-and-soft rubber lining devel- Goodrich Akron. Protection against physical abuse thickness acid- resisting brick. said thoroughly protected from the action the blast all points wear, and bearings and working parts are sealed from dust. total 6-hp. required for opera- tion. Polishing Adhesives and Grains UGLU new type water soluble abrasive adhesive made the Siefen Co., 5657 Lauder- dale Street, Detroit. Among the ad- vantages claimed for this bond for polishing wheels, belts disks are: Flexibility under all conditions and resistivity against temperatures 2000 deg. F.; tenacity grip abra- sive grains, resulting fracture the grain itself rather than rolling away the whole grain, thereby giv- ing faster cutting action and finer finish with more ting under heat, making possible force-dry wheels without harmfu! ef- fects; and low surface tension and high penetrating qualities, permitting penetrate the pores the grains well the cloth the wheel. Nuglu can applied cold with made three types: Type No. 245 for grains finer than No. 200 and down the grade; type No. 236 for abrasives from Nos. 100 200, and type No. 237 for grains coarser than No. 100. HROUGH error our issue June page 43, the impression was given that Idilite and Idilon were new cements for abrasives. Instead, these are the trade- names abrasive grits recently de- veloped one the largest manu- facturers abrasives expressly for use with cements made the Iding Disc Grinding Compound Co., Pierce Street, Milwaukee, and sold through this firm. There are two types Idilite grains, which are aluminum oxide abrasives. The types, etched grains, possess high capillarity and sharp cutting qualities. HIS new and smaller size (20 27-in.) Wheelabrator Tum-Blast airless centrifugal cleaner for small batch work. ane 4 | f — ; é IEFEN new polishing wheel adhesive made types according the range grit sizes. DYLITE Masterfold buffs are produced variety types according den- sity and treatment the specially folded cloth. use speed, plating solutions high acid content, Hanson VanWinkle Munning offering the Corning glass cloth anode bag. Wellman cast anode fishbone design said have four times the thick- ness the average anode the solution line. Type non-etched grains, the other hand, possess long wearing qualities and are said produce much brighter finishes when used with Iding cements. Idilon silicon carbide abrasive grain, chiefly applicable polishing gray iron all kinds. Cloth Buffing Wheels ASTERFOLD the name new buffing wheel, made the Udylite Co., Detroit, which the cloth folded such manner that presents multiple edges that are said cut instead rub and the same time provides air spaces be- tween the cloth plies dissipate the friction heat generated pressure the work. claimed that the buff bites into the metal with minimum pressure and will reduce buffing time anywhere from per cent. Composition held and pocketed that the efficiency the operation maintained with fewer applications the stick the wheel. also said produce better finish. The buffing action uniform over the face the wheel and ridging, pitting and chat- tering are said eliminated. Such buffs can used automatic hand operated machines. Optimum speed 8000 ft. per min. Plating Accessories LASS cloth anode bags one- piece, construction are now being offered Winkle-Munning Co., Matawan, Developed cooperation with the Corning Glass Co., these bags are in- tended resist the destructive action sulphuric acid high speed, hot nickel plating solution, with low (high acid), which render ordinary cloth anode bags short lived. Glass cloth quite flexible, and the anode YPE Metco metallizing gun weighs only The sealed gear case made Dowmetal, with brass housings for the ball bearings. Gas head dense pressure tight bronze, and the wire nozzles are also bronze, with hardened, heat-proof lining. EVILBISS type MBC-527 spray gun for porcelain and other ceramic materials incorporates strengthened wearing parts and materials that increase the life the gun under severe abrasive conditions. BELOW ITH one downward motion the Snaplock cover, the cup gripped instantly the new Paasche type high production airbrush. bag not sewed, but sealed special process one end and pro- tected from raveling the other end. Besides being recommended for acid solutions, this glass cloth bag also useful for many alkaline solutions. FTER two years testing and research, the Wellman Bronze Aluminum Co., Cleveland, has introduced new Fishbone anode for chromium plating. Cast shape, in- stead being rolled, the anode has more edges than other types and be- cause its distinctive shape said increase the throwing power the plating solution. Standard pat