The Iron Age 1938-12-29: Vol 142 Iss 26

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Bditer Art Bditer Metallar gical Bditor Associate Editors Consulting Washington Editor Resident District Editors Editerial Correspondents Lenden, England Cincinnati Beston Hamburg, Germany MBYER CHARLES Post Milwaukee San Franctece Toronto, Ontario Birmingham ALLISON Roy EDMONDs Jr. Buffale DECEMBER 29, 1938 Owned and Published CHILTON COMPANY Quality Control Steel (Incorporated) Larger Air Conditioning Market Obestnut and 56th Sts., 239 West 39th Philadelphia, New How General Electric Co. Handles Cable OFFICERS AND DIRECTORS MUSSELMAN, President High Strength Furnace-Brazed Joints Explained JOSEPH HILDRETH, Vice-President Increasing Content Cast EVERIT TERHUNE, Vice-President JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE, THOMAS KANE, CHARLES BAUR, Washington News CARROLL BUZBY, FAHRENDORF THE NEWS BRIEF Rate Activity Capital Goods BAUR, General Advertising Manager Weekly Ingot Operating Rate Member, Audit Bureau Circulations Plant Expansion and Equipment Buying Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ADVERTISING STAFF Emerson Findley, 621 Union Blidg., Cleveland Herman, Chilton Bldg., Chestnut Just Between Two Peirce Lewis. 7316 Woodward Ave., Detroit . B. nson, ar g.. ttsburgh Warren, Box 81, Hartford, Conn. Copyright 1938 Chilton Company Upon the pharmacist’s accuracy compounding prescription may depend the patient’s health— even life. similar way, accurate fine steel making has important effects industrial health and profits. Allegheny Ludlum engineers and metallurgists compound accurate and effective prescriptions for alloy steel users. They will gladly study your problems and recommend the type steel best suited your need. you wish, they can work out special analysis for any job, produce the steel exact specifications, and see that measures every requirement actual use. For further information, write Allegheny Ludlum Steel Corporation, Oliver Building, Pittsburgh, Pa. ALLEGHEN STEEL CORPORATION 14—THE IRON AGE, December 29, 1938 LUDLU PITTSBURGH, PA. How A-L recommendations often result substantial savings exemplified the following: After careful tests tool steel recommended, structural iron works reported that the life dies and punches used all types girders was more than double that tools used previously. Angle Shear Blade grade 602 was put into test use against blade made an- other steel. Three months’ continuous serv- ice proved the 602 steel blade superior every respect. ESTABLISHED 1855 THE IRON AGE DECEMBER 29, 1938 Vol. 142, No. Wishing You Happy and Prosperous New Year HERE are two old sayings that come mind thinking about wishes. One wishes were horses, then beggars could The other you wish for anything hard enough, your wish will come These sayings seem contradict each other, but actually they not. true that you cannot get horse anything else just wishing for it. But also true that you wish hard enough for something that compels you put forth diligent effort toward getting it, the chances are that you will get your horse your motor car, your promotion, your profit doing business what- ever that you wish for the point it. wish its rough state like soft and unhardened piece tool steel that will upset bend when you try cut with it. But subject the hot flame will and the quench bath work and becomes keen edged tool that willing and able turn the toughest material into finished reality. Now wishing our readers and ourselves Happy and Prosperous are not stopping just the wish, but you and are going work together obtain the reality. For the past five years, you and have wished together and worked to- gether the end that America might spared from the blight the defeatism which has muzzled enterprise and discouraged initiative and abolished freedom many countries the world. are going continue wish, will and work together for this during 1939 and more confidently and courageously than ever the light the marked progress made toward that end 1938. This year are going work shoulder shoulder make Amer- ican industry safe for democracy the one way can made safe, namely restoring its vanished profit margins, for nation can survive and people can prosper and progress unless the sustaining lifeblood profit courses through the veins its industry and its business. sp Perchloric Part ° ° MORRIS JOHNSON Chief Chemist, Crucible Steel Co. America, Park Works ° article continues the detailed description new perchloric acid proce- dure for the determination manganese all alloy steels without separation chromium, the first part which appeared the Oct. issue. The author herein high chromium silicon nickel copper steel (such 20, with, say, 0.10C), should noted that some the alloy combinations the four elements are slow dis- solve, become partially immune and retain metallic luster even with 1:1 The problem then becomes merely matter first heating such steels with ml. 1:1 until the metal decomposed. The excess then boiled off thick syrupy liquid, with the cover glass remaining the dissolving flask. The next step introduce ml. per cent HCIO, and take the fuming for one minute with dense cloud the HCIO, coming from the flask, and then cooling, the underside the cover glass should show red crys- sis finished described for the per- sulphate-silver nitrate oxidization. (Oct. issue.) The result shown the AgNO, method 0.725 per cent Mn, whereas 0.74 per cent 16—THE IRON AGE, December 29, 1938 ° ° first describes manganese determinations steels con- taining Cr, Si, Ni, and any one more tions, and steel. then discusses the effect molybdenum, vana- dium, cobalt, etc., steels being tested for content. shown the ZnO-PbO, method (old standard method). Method The old standard method (ZnO- chromium and iron away from the Mn, filtering off, and then icking definite proportion The first improvement tried the some hundreds tests, the following conditions were found essential for the method manga- nese determination: (1) All chloric acid odors must eliminated. (2) the perchloric acid used per test exceeds certain amount, low and conflicting results are obtained, these being most likely due some the manganese reverting in- soluble basic oxide which filtered off with the excess and chro- mates lead. (3) All chromium must con- verted chromate heavy fuming with HCIO, for least one minute, and until red crystals show the cover glass cooling. (4) The PbO, and chromate lead must washed with perchloric wash, chromates will run through muddy decomposition product. (5) Both the standard steels and the samples being analyzed shouid contain approximately (within one two per cent) the same amount chromium. The chromium can easily adjusted the standard steels adding dichromate the low-chromium the plain carbon steel standards, thereby mak- ing them suitable for comparison with high chromium steel samples. The foregoing notes also apply the final method developed, that the method, with the exception note No. Details Method First weigh 0.100 gm. drillings into 125 flat bottom pyrex flask having lip, and then add ml. 1:1 HCl. This heated slowly while the cover and until the metal decomposed, after which boil down very slowly syrupy liquid, but lower. The cover and side walls the flask are then rinsed down. Add ml. per cent HCIO, C.P. Then boil down with the cover until all chromium converted red chro- mate, after which heat boiling for one minute longer the clock, during which time heavy white fumes pour out from under the cover flask. number tests, say more, are being run together, bring them all slight fumes, then lower the heat un- der all but three tests. These three are then fumed described and re- moved from the heat. The stove shown solved one time. Three tests are then fumed heavily for one minute and removed and treated described. — AS 45 TR 4S cA a : | a a | 1 1 r ‘ 4 ‘ { N The red crystals are again rinsed from the cover glass and side walls the flasks, ml. H,O added all tests after which they are all brought boil, and boiled with the cover off for three minutes remove all chloric odors. Now add ml. only, and more, 1:1 and boil for four minutes, remove from the heater and add gm. specially prepared PbO, brown shade.! Boil for three minutes and cool, after which filter with suction through washed ignited asbestos that has pre- viously been heated with per cent solution) and then washed with H,O. Wash this residue, which consists the insoluble and spent PbO,, ten times with ml. per cent C.P. HCIO, diluted 500 ml. with H,O. After every other filtering, scrape off the layer PbO,, etc., down the asbestos, otherwise the filtering and washing will slow. also, scraping omitted, this etc., has decided tendency retain pink color and will have washed about times remove all permanga- nate. properly prepared plug will Titrate the pink filtrate and wash- ings colorless liquid with sodium arsenité standard. This standard- ized with plain steel about the same manganese content, which potassium dichromate added the start bring the content about that the samples. Refer the description manganese 18-4-1 high speed steels the Oct. issue Ace. Consult also Table which demonstrates the effect chromium the manganese percent- age factor the arsenite standard solution. The arsenite titrations should made soon possible after the tests are cold and filtered from the lead salts. The suction flask heavy glass 260 ml. capacity, 14.5 cm. tall, with side outlet tube, and takes No. stopper, being standard size. The 125 ml. pyrex cone dissolving flask with lip strictly flat bottomed, hav- ing straight side walls. Fig. shows the improved type stainless steel ventilating hood used for all these experiments. Solutions Used Foregoing Silver gm. per litre Ammonium persulphate 240 gm. per litre H,O. Sodium gm. per 3600 ml. Morris Johnson, 4th edition, pp. 577 602. One gram sodium arsenite 3600 ml. equivalent per ml. about 0.072 per cent manganese when 0.100 gm. taken for analysis for plain steel, and about 0.079 per cent for chromium steels above 4.00 per cent chromium. This description the PbO, method given for three rea- sons (1) Some who not have many manganese determinations may flask with lip and cover glass. Boil down heavy fumes, and fume heavi- boiling for least one minute. The solution will red, and the drop the lid must red and contain red crystals cooling. For all experi- ments date, unless this heavy fum- ing done the results not check. Cool the solution carefully, rinse off the liquid film and red crystals from the cover glass and beaker walls, and add ml. H,O and boil for three stove, such that used for dogs” which invaluable the carry- ing out numerous analyses with perchloric acid. prefer titrate the disappearance the real permanganic pink shade obtained this first method, even though involves one filtration. (2) The chemistry the PbO, method interesting. (3) was the development this first method that pointed the way the use the oxidation the presence any amount chromium tung- sten, avoiding ZnO NaHCOs sep- aration chromium, any filtra- tions. The final procedure developed the same the point substitut- ing the for the the Park Plant was found that the procedure was great boon until the substitution the method was thought and tried order eliminate filtration first convert- ing all chromium into chromates fuming Manganese High-Chromium Steel The laboratory procedure for the new silver nitrate-ammonium persul- phate—perchloric acid method for de- termining manganese mium steels, with ranging from about 0.10 1.50 per cent, fol- lows: Dissolve 100 mgs. the sample straight wall, flat bottom, pyrex cone minutes without the cover, order remove all ClO, smell. After cooling add ml. AgNO, and ml. Boil for three minutes, and then cool trough running water about deg. Titrate with the arsenite standard disappearance the tints, getting yellow end point. Use foil No. 55a similar which equivalent dichromate has been added the start. dardize the sodium arsenite putting through the entire method plain steel standard, which dichromate has been added order bring the chromium content about the same that the test specimen. Or, standard steel alloyed with chromi- and manganese content about like that the test sample can used. Any titration solution can retitrated reboiling with ml. persulphate, then cooling and retitrating. some cases advantageous reboil the steels for nine minutes, as, for ex- ample, reboiling usually corrects dis- agreements 0.02 0.04 per cent. method for high chromium- THE IRON AGE, December 29, silicon-nickel-copper steels, which the manganese ranges from per cent, follows: smaller amount this type steel weighed delicate balance which has sensitivity ten divi- sions for each mg. For 4.0 per cent manganese and 12.0 per cent chromium, high carbon steel, weigh and mgs. sample, and proceed exactly the same the 0.10 1.50 per cent range Mn, except that the Suitable standard mixtures are taken order get the manganese value the arsenite solution for manganese range, else similar approximately the same manganese and chromium con- tents will answer for standardizing. the foregoing method, the fol- lowing results were obtained: using mgs. Bureau standard No. 100, containing 1.39 Mn, which mgs. and mgs. stand- ard No. 55a were added, arsenite factor ml. equals 0.069 per cent was obtained, and using mgs. the No. 100 standard and add- standard No. 55a, factor 0.0667 was obtained, showing that the pro- cedure gives agreeing factors. actual test for content, heat con- taining 3.52 per cent was found the test show average 3.53 per cent two tests. Further- more, when this heat with ml. persulphate, the con- tent again showed average 3.53 per cent two tests. show the precision the test with high steels, consider that one heat containing 12.15 per cent Mn, the test showed 13.33 per cent Mn, and reboiling showed 12.17 Mn. factor for this test was secured from per cent stand- ard. interesting point out another sensitive ten divisions for each milligram, into the cone flask, along with dichromate and No. 55a ingot iron. This mixture can then dis- solved described for the steel and subjected all the treatments al- ready given. The contains 34.76 per cent manganese. For ex- ample: mgs. 14.0 per cent steel would equivalent 0.14 3.5 mgs. Mn. Ten milligrams mgs. Mn. The results shown this procedure, mgs. basis are follow: mgs. per cent steel gave 0.077 per cent Mn; mgs. per cent steel gave factor 0.076 per cent Mn. certain heat analysis the foregoing method mgs. gave determination 12.50 per cent Mn, for Chemical Analysis Special Steels,” 4th edition, pp. 578 582. TABLE Manganese Factor the Arsenite Standard Affected the Presence Chromium the Oxidation Standards No. 20b 0.673 per cent No. added ........ mg. (1.41 per cent Cr) mg. (equivalent 3.18 per cent Cr) mg. (3.53 per cent Cr) mg. (3.89 per cent Cr).. mg. (4.24 per cent Cr) mg. (4.59 per cent Cr) mg. (4.95 per cent Cr) Arsenite Factor Per Cent when 0.1 gm. Taken for Analysis. 0.070 per cent 0.072 per cent Effect Chromium Manganese Per Cent Factor Steels, When the Chromium Alloyed with the Steel Bureau Standards: No. 20b (no Cr, 0.637 Mn) No. Bessemer (no Cr, 0.915 Mn) ....... No. 100, rail standard (0.18 Cr, 1.39 No. Cr, 0.707 No. 106 (1.29 Cr, 0.484 Mn) 0.072 per cent 0.074 per cent 0.074 per cent Showing Effect and and High Arsenite Factor 8.0 Mo, 4.0 Cr, 1.23 1.7 ..... No. (17.56 Cr, 9.44 Ni, 0.554 Mn) 0.080 per cent IRON AGE, December 29, 1938 and the 30-mgs. analysis gave de- termination 12.25 per cent Mn. testing this same heat persulphate precipitation and titration with fer- rous ammonium deter- mination 12.15 per cent was ob- tained. reboiling this same heat with ml. persulphate, the percentage factors were 0.077 per cent and 0.076 Mn, and this new procedure gave manganese determination 12.23 per cent using the 25-mg. sample, and 12.23 per cent using the mg. sample. Effect The following takes into account the effect molybdenum with man- ganese about 1.5 per cent. Steels containing per cent and per cent and per cent may require initial heating mgs. with ml. 1:1 until the steel completely decomposed. Boil syrup and then add ml. per cent and then boil heavy fumes and continue boiling manner for one minute. The flask removed heater, and the drop the underside the cover glass should show red From here the method already out- lined followed, taking care fume heavily for one minute and oxidize Rezistal stainless steels containing may require the treatment pre- vent the drillings from becoming im- mune the When immunity occurs part the steel will remain un- dissolved the bright metallic state. The results shown the above procedure are follow: standardiz- ing mixture 1.39 per cent rail standard plus mgs. dichromate gave percentage factor manganese 0.100 gm. basis per ml. 0.071 for one test and 0.070 for second test. For one heat per cent steel, using 50-mgs. sample, the AgNO, method showed 1.65 per cent one test and 1.66 per cent another test, and deter- mination the method showed 1.62 per cent Mn. For dif- ferent heat per cent steel, the method showed 1.38 two successive tests, and the PbO, test showed 1.37 per cent Mn. Effect Vanadium The effect the element vanadium under conditions the method devel- pe Sa pe o V W a 1 ( oped far may one slight in- terference. This taken into account adding equivalent amount vanadate. For example: mgs. will equivalent about 1.12 per cent vanadium 0.100 gram sample. The following shows the percentage per ml. 0.100 gm. basis for vari- ous plain steels with vanadium added: Bureau standard No. 10d, 0.100 gm. 0.915 per cent plus mgs. gave 0.069. This same stand- ard without gave 0.065 arsenite factor. No. 100, rail standard, 0.100 gm. 1.39 per cent plus mgs. gave 0.070. The same standard with- out gave arsenite factor 0.067. The above No. re- boiled with ml. persulphate and with gave 0.074; without gave 0.070. The above No. 100 standard re- boiled with ml. persulphate, with gave 0.076; without gave 0.074. All the above shows that vanadium the usual ranges has very little effect the factor values. Vanadium and Chromiurn Concerning the effect vanadium and chromium the AgNO,—persul- pointed out that the presence vana- dium with high chromium does not have appreciable reaction effect factor values but indications far are that causes slightly higher fig- ures some plain, low chromium combinations. Effect Cobalt Other than pink color the cobalt (37 per cent Co) there interference cobalt. This pink can easily compensated for prepar- ing foil containing all coloring ele- ments such chromium and cobalt the same amounts, but with manga- nese. The source cobalt can cobalt low manganese. For exam- ple, there such metal, with man- ganese low 0.06 produced com- mercially containing per cent cobalt and higher. this foil can added excess the titrating solution, which will eliminate from the foil any brown shade due the 0.06 per cent manganese. the chromium present should high per cent, then not the slightest pink color the co- balt appears. therefore entirely eliminated from the end point color 2—By far the best type hood use with perchloric acid one such this made stainless steel. wooden hood always endangered charing. dichromate added, even though about mgs. metallic cobalt should steel, when using 0.100 gm. sample for the analysis. Method for Steel per cent cobalt steel contain- ing per cent tungsten and per cent chromium was dissolved heating 0.100 gm. ml. 1:1 (60 per cent C.P. diluted with equal volume water). When the steel dissolved, the so- lution taken heavy fumes and boiled heavy fuming for one minute. removing from the heater and cooling there should red crystals the inside surface the cover glass. The cover and sides flask are rinsed down with jet and ml. added. The contents flask are boiled three minutes with the cover off the cone flask. After cooling ml. AgNO, ml. are added, and the solu- tion then boiled nine minutes. Cool and titrate all brown tints yellow, matching against the usual foil, which equivalent amount tung- stic acid added the start. The tungstic acid was not removed before titration. Using specimen about Co, Cr, and 0.85 three tests the showed 0.62, 0.63 and 0.64 per cent respectively, and from test the same sample the old standard method and 0.64 per cent was obtained. High Manganese Still another way determining high manganese involves solution the steel perchloric acid and the precipitation the manganese oxide. advantage that larger weights can used and the complete solution the chrome carbides assured. Mn, dissolve gm. sample ml. perchloric acid plus ml. using 600 ml. beakers. Heat until the metal dissolved, then take heavy fumes until the black carbide resi- due gone. After cooling add 100 H,O and boil for five minutes, boiling off all (CONCLUDED PAGE 22) THE IRON AGE, December 29, QUALITY CONTROL STEEL RALPH BISBEE Chief Inspector, Westinghouse Electric Mfg. Co., Mansfield, Ohio. ° ONTROL quality West- inghouse products based, large degree, the quality control “bought-outside” material. error large quantity material that defective were passed through the receiving department, the unfortunate results below would inevitable (1) Production suffers. The production department depends upon this material when starts through the manufacturing proc- esses, and proves defective, production delayed until new material available. (2) Extra expense incurred, due extra handling and lost time. (3) Quality suffers. emergency would necessary use the material sacrifice quality. Therefore proper con- trol quality maintained the receiving department assures product that will give the maximum life without trouble. Over period years Westing- house has prepared from experience manual. This manual lists all parts that are detailed 100 per cent spot checked, also material that must approved the laboratories be- fore acceptance. incoming material, requiring important checks for physical requirements, are routed through control laboratories be- fore release stock. Inset shows steel being tested for elongation. IRON AGE, December 29, 1938 hy | ° 4 j j 4 quiring important inspection for phys- ical requirements, electrical, thermal chemical, routed through control laboratories (Fig. before being re- leased the stock room. The control system for steels in- teresting and will described the following paragraphs. which will applied the steel are synthetic enamel, black japan, vitreous enamel, nickel plate, chromium plate, and many others. Considering the volume and variety finishes and ap- plications handled, obvious that very strict control system necessary. ceived, checked inspectors for quantity and quality before its ac- ceptance. Samples are taken from shipments all deep drawing steels, regardless kind, and sent the laboratory. They are passed through three physical tests, (a) cup test regular Olsen testing machine de- termine ductility; (b) Rockwell hard- ness tests, determine surface hard- and (c) elongation tests regular Olsen universal testing ma- chine determine elasticity. From experience has been found that the above combination tests enables the metallurgist predeter- mine the steel will draw the plans specify. There have been rare cases where the grain has been abnormal, which case the tests would not detect the abnormality. However, such cases have been few and far between. The three tests, however, completely sufficient predetermining before release whether the steel will perform satisfactorily. Production thus not interrupted and losses are kept minimum. which will finished with paint shall have surface with enough tooth for proper adhesion. For example, all the Westinghouse refrigerator cabinet wrapper sheets which require white Dulux painted surface are checked Samples in. square are taken from each shipment and routed the labo- ratories. The laboratory cleans off the surface the steel, places photomicrograph machine, and com- pares (at diameters) with “go” and “no go” standards for surface teething. The standard photomicro- graphs are shown Fig. The one sample (No. steel that too smooth for proper adhesion. The sur- face has been cold worked with smooth rolls the point that practically Refrigeration q ° ° 2—Standards used for compar- No. ing surface teething. White area, top teeth; black base diameters. Range deal Surface Adhesion Maximum Allowable No. Std. Scratch Test Thru Steel No. ond sample Fig. (No. shows ideal tooth condition for proper adhesion. Notice the uniformity and depth the teeth. third sample Fig. (No. shows the maximum roughness allowable. The two lower views (Nos. and show steel subjected standard scratch test. will noted that sam- ple No. has better adhesion than sample No. and No. not quite good No. These samples were processed with regular primer and finish coat Dulux the same time, and were baked the same ovens. The scratch test sample No. shows both the finish coat removed the base metal, due the fact that there were teeth hold the primer coat the steel. sample No. the finish coat moved, but the primer coat still ad- hering the teeth suriace the steel. Several years ago when these stand- ards were being developed, the steel companies had considerable difficulty trying standardize surface that would meet the Westinghouse require- ments. However, some steel companies finally worked out method shot blasting the final cold which results very economical and uniform “toothed” finish the steel. first there was much opposi- tion trying standardize proper adhesion for paint surface, but after way was found the steel compa- nies this the trouble disappeared. Occasionally steel supplier becomes careless and allows the final cold roll become worn the point that does not give the proper tooth the surface the steel. this case the receiving laboratory rejects the ship- ment. Steels vitreous enameled are checked follows: (A) Bond test. Following the regu- lar physical tests sample sent the laboratory where given ground coat enamel. Then tested regular impact tester, after which the percentage area with the enamel still adhering determined. Limits have been set that de- termination can made whether the steel satisfactory for bond ad- hesion. The height drop weight varies according the thick- ness the steel. Experimentation now under way THE IRON 29, 4 OOO the laboratories check the surface means comparator. The photo- graphs are explanatory. The steel with the smooth surface has been taken from lot that has given trouble, due poor enamel -adhesion, while the steel that shows uniform teething comes from lot that has proved satisfactory actual tésts after enameling. This method may supersede the regular bond test meth- that used most control labora- tories. (B) Sag test. Tentative sag tests have been established through the Porcelain Enamel Institute and are be- measured. The results obtained are comparison type. (C) performance test. Every three months Westinghouse grades each supplier enameling steels. This grading arrived comparing actual performance and examining rejects, both the ground coat and finish coat. committee, composed the superintendent the enamel division, the tool division, and the chief inspector, grades the sup- pliers and sends report the pur- chasing department, together with chart. The grading based the following symbols: AA, very satisfac- shows, left, good adhesion the new photo method, and right, poor adhesion surface. diameters. ing tried out the committee mem- bers charge. The tentative sag test will sent all who are interested, and tried out before definitely established standard. this way all variables encountered different types enameling can taken into consideration. However, the Westing- house method, which has been used for the past several years, lines very favorably with the institute’s tentative test, except for size samples and fulcrum points. The samples tested Westinghouse are in. in., placed rack nickel chromium with 9-in. centers, the entire unit then being placed the center furnace which has been heated 1580 deg. The samples remain this heat for ten minutes, after which they are removed and allowed cool room tempera- ture. Then the sag from the horizontal 22—THE IRON AGE, December 29, 1938 tory (above commercial) satisfac- tory, satisfactory, but not good supplier falling into the class for two more months placed the unapproved list manufacturers. then necessary for this company send several shipments sam- ples before they are again placed the approved list, the samples are found satisfactory the labora- tory. Other steels, such cold rolled strip for nickel plating, are checked similar manner. However, the meth- varies according the application. adequate quality control system means “prevention rather than cure.” Adherence intelligent central scheme eliminates confusion and mis- understandings with suppliers; pro- duction flows evenly and schedules are met; costs are maintained and higher quality results. Perchloric Acid (CONTINUED FROM PAGE 19) chlorine fumes, that is, all smell chlorine. Dilute 300 ml. Neutralize some the free acid with 1:1 NH,OH and introduce gm. ammonium persulphate. Boil for min. after the manganese oxide precipitate forms, and then filter through double No. paper. Wash times with water, and transfer washed papers origi- nal beakers and add, usual, mea- sured excess ferrous standard. Then back titrate this excess with the equivalent standard. Add gm. more ammonium persulphate filtrates and boil for min. note more manganese precipitates. pre- cipitate forms, filter above and tit- rate, adding the original. sure the persulphate crystals are full strength, otherwise low results may obtained. 3.75 per cent manganese steel standard gave factor about 0.375 per cent when gm. was taken for analysis. Or, also pos- sible prepare synthetic standard, for example: 0.3 gm. per cent steel plus 0.6 gm, ingot iron No. and 0.3 gm. dichromate, the two former totaling 42.114 mgs. Mn. Ore The same weights ground ore are used for steel are digested ml. concentrated hy- drochloric acid until only floating residue remains, The same amount per cent perchloric acid used steel then added; take heavy fumes and then complete the analysis described the section devoted manganese steels. The arsenite solution can stand- ardized Bureau iron ore which manganese has been previously determined the old standard pro- cedures. Satisfactory and consistent results have been obtained the fore- going procedure. Allis-Chalmers Mfg. Co., Inc., space the Industrial Office Building Corp. building 1060 Broad Street, Newark, J., for New Jersey sales office. Fellows Gear Shaper Co., Springfield, Vt., has moved its Detroit office from 616 Fisher Building 814 Fisher Building. é market for air conditioning equipment may expected defi- coming year. can base our op- timism, seems me, the follow- ing three factors: consumer acceptance and popularity. 2—Better and wider distribution. 3—The introduction broad line packaged units capacities tons for both inside and remote installations with duct systems. Installed equipment sold mem- the Air-Conditioning Manu- facturers Association anticipated total $85,000,000 1937 compared with sales $50,000,000 1936. increase per cent horsepower the 1937 utility installa- tions over 1936 was also reported. The average horsepower estimate 20.1 for 1937 showed slight increase over the average for 1936, and the increase tels, theaters, restaurants, department stores, hospitals, mortuaries, etc., that installed air conditioning 1937. According available statistics the residence applications account for less than per cent the 1937 volume. appears that while the residential mar- ket should most lucrative one, and market that should carefully Larger Conditioning Market Through ° Distribution DANLEY Manager, Air Conditioning Department. Westinghouse Electric Mfg. East Springfield, Mass. ° studied and cultivated, will follow the smaller commercial application development. Here again product and distribution seem least partial- responsible for the failure resi- dential sales more significance. All indications point expansion the market the direction ap- parel shops, markets, offices, hospitals, theaters, restaurants, schools, depots, barber shops, department stores, ete. And certainly have worry about saturation this market for many years. The vast market awaiting the indus- try, provided the product and distribu- tion problems are solved, reflected from the fact that there are some 40,000 dry goods and small department general stores; 125,000 64,000 beauty shops and barber and about 58,000 drug stores. Add this list the thousands candy stores, small offices, apparel shops, banks, theaters, mortuaries, and dozen additional prospects, and you will have some idea the magnitude the market. The prospective market here cited represents going concerns; does not include new building and construction that now hitting its stride. This mass market now opened through the medium “packaged” air conditioning, observed trend 1938 but important factor 1939. important because elimi- nates the engineering the refrigera- tion cycle unit installations from tons. believe that the intro- duction the packaged unit the most significant contribution the expansion the air conditioning mar- ket since its earlier stages develop- ment. packaged air conditioning, mean unit for the contractor which has all refrigeration connections, in- ternal wiring, piping refrigerant and the like—factory built and tested. The introduction packaged units will increase the potential market be- makes for wider and better distribu- tion. eliminates the need for refrigera- tion work the job. opens the air conditioning business the smaller heating and ventilating contractors who have stayed out because technical engineering diffi- culties. makes for better lower-cost installa- tions. Much the technical planning and contract work eliminated. The units are lighter weight and smaller size than formerly. Not only are Westinghouse predicting the opening this mass THE IRON AGE, December 29, ; Few ° ° A | a market, but have changed our dis- tribution take care the anticipated increase sales and promotion. This thinking our part the result many surveys, field experiences and carefully planned promotions. Large Contractors for Big Jobs Although Westinghouse doing everything make easy for small contractors apply air conditioning ordinary homes and shops, the large heating and ventilating engineering organization remains the backbone for big custom-built jobs. Where small contractor uncovers complicated ap- plication, expect provide direct tie-in with our regular engineering contractors make available up-to- the-minute engineering practice. Approximately 100 authorized engi- neering contractors many cities had produced very satisfactory vol- ume 1937, but during the recession this volume decreased half. analyzing our territories, made some startling discoveries. The 100 engineering contractors had territories averaging almost half state each. Yet they had been cultivating only their own cities. maps which pre- pared, the distribution picture showed grouping installations and very near headquarters cities, but prac- tically nothing the rest the ter- ritories. Upon further analyzing each terri- tory discovered that outside the headquarters cities there were total 400 other important cities each with good-sized trading area, each with good business, each filled with stores, hotels, restaurants, beauty parlors— every other commercial outlet for air conditioning. Those towns had not been cultivated. But half state very large territory. The only way cultivate such broad business opportunities set our present outlets distribute associate engineering contractors the important smaller towns within their territories. And with “pack- aged” line units feel through Set-up Registers for Metal Working Machines RECENT development for im- proving the efficiency vari- ous types metal working ma- chines increasing both speed and accuracy the setting operation the set-up register. These devices are commonly high precision types revolution counters. typical counter for this purpose shown Fig. The drive shaft the counter register connected appropriate means the adjusting shaft, screw- down, spindle feed the machine. Any adjustment the machine 24—THE IRON AGE, December 29, 1938 down appears figure the dials the regis- ter. These figures may regarded scale marks the ver- tical slide the machine, which can read any point and recorded for future use. The register may arranged re- cord settings even ten thousandths inch, desired. The operation press LEFT IG. ball-bearing worm counter frequently used set-up register. The drive shafts, which may project top, bottom, front, rear ends, are connected the adjusting drive, gears, screw the machine. RIGHT applied the right screw cold forming and shearing machine. these distributers have something worth while offer these associate contractors. have eliminated the mystery and tion work the job. Provision Made for Residential Market give these smaller-town heating and ventilating representatives year- around, all-market, one-brand line sell, Westinghouse Home Heating and Air Conditioning will offered. The line has been sufficiently expanded cover the field. There are now three lines gravity coal-fired furnaces and line gravity gas-fired furnaces; conversion oil units; boiler-burner units for oil and later for gas; winter air conditioning units for oil, gas, hand stoker-fired coal; and for summer cooling, pack- aged units which may installed the supply duct winter air condi- tioning systems add summer cooling and dehumidifying and convert the sys- tem for service. brakes with their long dies espe- cially improved the use set-up Whea the press brake has been accu- rately adjusted for new die, the set- register each end The two readings are not likely the (CONTINUED PAGE 62) IG. Crude rub- ber formerly stored (right) and now stored double- faced pallets. ANUFACTURERS cable. particularly the larger and heavier varieties, have been with the problem finding more economical means handling process reels cable between manu- facturing operations. known method—such cradle-reel trucks, conveyors, manual labor, and turning with the aid turntables crutches—has been tried. Some the methods have provided fairly satisfac- tory results certain phases the work, but few could always adapt- varying situations. many in- How General Electric Handles Cable ° Supervisor Production, Appliance Merchandise Department, tric Co., Bridgeport, Conn. ° ° stances these systems contrast the old and new tying-up floor space, lacked flexibil- ity, required excessive labor and time, and even introduced safety hazards. Bridgeport, General Electric concerned with the manufacture all cords and cables carrying rubber similar synthetic insulations. Among the raw materials involved are: rub- ber various forms, waxes, powders, yarns, paper, copper, lead, and metallic tapes. bulky and handled heavy units. With large volume movement, the handling and storage this material problem. presents major methods stocking representative ma- terials indicates the economies sible when the problem scientifically studied. Fig. shows crude rubber storage both formerly stored (at right photograph) and pres- ent. Today the baled rubber placed pallets the freight car when stored. The pallets sometimes tiered four-high. Rubber delivered the point consumption pallet units and handled directly from the boxes when used. pos- are Even 4000-pound loads various powders required for THE IRON AGE, December 29, = LEFT IG. loads powders for rubber fork-type industrial trucks without the use pallets. BELOW Large reels cable weighing from 7,000 11,000 each are readily adjustable fork- trucks. pounds can handled fork truck and pallets (Fig. 2). Anyone familiar with the handling bagged material knows the expense, waste, and dirt which involved handling not scientifically directed. Heavy drums formerly were merely piled top each other, resulting both much labor and damaged drums. Today similar drums are handled pallets and although there space saving due the limited headroom, the handling and damage savings are ap- preciable. Lead any pig metal may dan- gerous and expensive when handled hand. Fig. shows the neat stor- age piles possible with the application fork trucks. The forks are inserted under the inverted lip the pig, and 26—THE IRON AGE, December 29, 1938 § Pa | | units. The lead received barges 4000-pound piles and handled that same unit the point con- sumption. Formerly, was handled 48-inch-square skids which consumed considerable floor space the lead presses. Today the expense placing lead storage approximately per cent the former amount. new G-E method storing band steel now standard. Here again the material handled unit from the point completion the plant the point consumption. Then the strapping cut and mag- netic push-button controlled electric hoists are used place the heavy coils payoffs. almost unbelievable re- duction spoilage has been achieved result improved handling meth- ods. Accidents have been greatly re- duced. Hand-pallet trucks prove desirable for very particularly where power-pallet trucks are avail- able only periodically. Heavy fork trucks may used for moving large reels copper conduc- tor finished cable, cable various drums. Incidentally, this was the first installation fork trucks for the handling reels. order make the contemplated use practical, was necessary for the truck manufacturer develop motorized adjustable forks controlled push buttons ABOVE 5—Former me- thod (right) stor- ing reels copper conductors, contrasted with new standard practice (left). RIGHT IG. 6—Smaller reels copper conduc- tors stacked eight reels pallet, and tiered five pallet-loads high. operator’s platform. The forks were specially shaped provide surface contact for all reels handled. commonplace handle reels weigh- ing 7000 pounds (Fig. with the trucks. Reels weighing 11,000 pounds have been handled thus. Due the presence considerable and other powdered compounds, gas engines could not utilized for THE IRON AGE, December 29, 7—Coils insulated wire are stacked flat pallets and tiered four pallet-loads high. the 24-hour service required these trucks. addition the exhaust blowing compounds around ing areas, was felt that carbon monoxide might hazard certain areas under mezzanine floors. The steel-encased battery the rear the truck was developed manufacturers that the trucks could operated for three continuous shifts each day with but one change bat- teries. batteries are changed very quickly and easily using ad- justable conveyor type able tables. The savings realized the use these trucks have even surpassed those anticipated, having enabled better utilization manufac- turing equipment addition duced handling expense. the right, shows the for- mer standard practice for storing reels containing copper conductors. prevent the wire from becoming tan- gled, was necessary. place the reels the edges the flanges. providing supplementary frame which could dropped place top the standard wood and steel ground the same photograph now possible handle reels from in. in. diameter pallet units and tier them like any other palletable product. earlier use the same idea us- ing wooden supplementary frame held place metal dowels wooden pallet, shown Fig. Some idea the savings space, possible with reduction handling SOR 28—THE !RON AGE, December 29, 1938 ° ° IG. Cable sold compara- tively short lengths wound reels which, means elevating fork truck, are tiered five reels high. > ° 4 expense the storing reels cer- tain types finished cables which can- not stored flat the reel flanges, indicated this view. Much has been done storing coils insulated wire (Fig. 7). Each pal- let load weighs 3500 pounds. Note that the operator can place two pallet loads top two pallets one op- eration. Certain types cables, such Parkway, Entrance, and all rubber portables, are frequently sold com- paratively short lengths. Formerly the Content XPERIMENTS the use manganese ore place ferro- manganese increase the content low-manganese irons are Trade Journal. issue The author the discussion, Ramaseshiah, foundry superintendent the Mysore Iron Steel Works, Bhadravati, India, states that the aim the experiments was determine the possibility eliminating the use ferro-manganese additions the ladle cupola utilizing manganese ore added directly the cupola charge. reels were stored the flange edges, taking considerable space and mak- ing most them very inaccessible. With the use fork truck, the forks are inserted just below the up- per flange the desired reel, and the reels above are all lifted off one op- eration (Fig. 8). The pile then set the floor and all but the reel de- sired lifted and put back place. Protectors are slipped over the forks for this operation prevent damage the cable. pallet trucks both the open Cast Increased the first experiment, the ore, sized in. diameter, was added directly the metal charge. The pick-up this case was found very small, about 0.17 per cent. was adduced that most the material must have been lost the cupola slag. the second experiment, the ore was mixed with coke breeze expe- dite reduction and charged over the coke layers the stack. This method cent Mn. the third experiment, powdered and closed pallet type find their place supplementary equipment this de- partment. Noticeable features the new method handling and storing these materials and finished products are neater housekeeping with ac- companying ease accessibility older stock that can consumed shipped first without extra handling expense. good criterion follow that your handling methods can im- proved until you eliminated handling. Ore Additions ore was mixed with coke breeze and added between the metal charges. This procedure resulted pick-up 0.37 per cent Mn. Ore Put Containers Ore, broken small pieces, mixed with coke breeze and soda-ash and packed cast iron containers and placed the stack top the coke charges, was the procedure tried the fourth and fifth tests. The gain these two experiments dropped only 0.26 per cent. (CONTINUED PAGE 61) Results Experimenis the Use Charge Grades Test charge No. Foun- serap cent 0.28 0.28 every case the weight manganese ore added was containing 34.3 per cent Mn. pected Mn. cast pected sample ingot pick- melt (aver.) mold Per Per Per Per Per cent cent cent cent cent 1,03 0.61 0.45 0.17 0.22 1.03 0.50 0.63 0.35 0.466 1.038 — 0.75 0.37 0.493 1.03 0.54 0.26 0.36 1.20 0.63 0.71 0.26 0.36 0.99 0.54 0.72 0.86 0.44 0.52 0.85 0.88 0.46 0.61 Manganese Ore the Cupola Lime- stone Method adding the charge manganese ore Lbs. ewt. ore charged first charge. Ibs. ore added over first four charges, with addition Ib. coke. ore charged between first and second charges. ore mixed with two baskets coke breeze with addition lb. soda-ash and tar bind. This was packed cast iron troughs and charged between first charge. Do. do. do. Alternate layers ore and coke breeze with small amount limestone powder put baskets and placed bed and over this the first charge iron was charged. but with above, addition about soda-ash. 30 Do. do ao. basketful coke breeze weighs THE IRON AGE, December Sy ¥ Fi : High Strength Furnace- the first questions occur prospective user any metal- joining process is: strong the resulting joint?" Properly made furnace-brazed joints have been shown have great strength, which the case copper-brazed assemblies, attributed the alloying effect between the copper and the iron and knitting effect between the two iron surfaces. This article the eighth the series electric-furnace brazing, begun Mr. Webber THE IRON AGE Sept. made laboratories have shown general that furnace-brazed joints have great strength. some joints have been found have greater strength than the parent metal, and such samples break the parent metal rather than brazed joints. and breakdown tests The actual strength which will obtained any assembly depends upon number factors such cleanliness the surfaces within the joints, analysis the parent metal and brazing metal, tightness the joints, time the heat, furnace temperature, subsequent heat treatment, etc. can probably said safely that the average copper-brazed joint has considerably better strength than cop- per. This can traced alloy- ing effect between the copper and the iron, and knitting effect between the two iron surfaces, both which con- tribute good strength. not safe count obtaining the strength steel within copper brazed joints production, but with good supervision the above factors reasonable expect the strength about mid- way between the strength copper and the strength the steel used. The following examples and bring this out more clearly. Some very interesting data the shear strength copper-brazed joints under various conditions have been collected George Oswald and Walter Homan the National Cash Register Research Laboratory. Their results are given the accompanying charts. All samples were the 30—THE IRON AGE, December 29, 1938 out” type consisting 9/32 diam- eter steel rods copper brazed into wash- ers similar material 5/32 in. thick, the copper fillets having been removed after furnace brazing order make the results accurate possible. Effects Tightness Fit Joints The first investigation was de- termine the effects the tightness fit the strength copper-brazed joints. Ten samples were prepared for each four different degrees tightness, varying from loose joints with 0.003 in. gap 0.015 in. drive fit. The results are plotted Fig. showing the minimum, average, and maximum values obtained testing Shear Str