The Iron Age 1939-02-16: Vol 143 Iss 7

FRITZ FRANK President J. H. VAN DEVENTFR Editor ROWAN News Editor WRIGHT Managing Editor MILLER Machinery Editor FINDLEY Editor Emeritus Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati F:DRMUC Boston Hamburg, Germany MEYER Milwaukee (*HARLES Post San Francisco SANDERSON Toronto, Ontario ASA ROUNTREE, Jk. Birmingham ALLISON Newark, N. J. TURNER, JR. Buffalo Roy St. Louis Owned and Published by CHILTON COMPANY (Incorporated) Editorial and Executive Offices 239 West 39th St.. New York, Publication Office Chestnut and S6th Sts., Philadelphia. Pa, OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT B. TERHUNE, Vice-President WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN H. VAN DEVENTER, JULIAN CHASE, THOMAS L. KANE, CHARLES 8S. BAUR, G. CARROLL BUZBY, P. M. FAHRENDORE Vice-President Vice-President Vice-President BAUR, General Advertising DIX, Manager Reader Service Member, Audit Bureau of Circulations Member Associated Business Papers Indexed in the Industrial Arts Index Published every Thursday. Subscrip tion Price: United States and Pos sessions, Mexico, Cuba, $6.00; Can Single copy, 25 cents. Cable Address, “Tronage, N. Y."' ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg. . Phila 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., W. B. Robinson W. J. Fitzgerald 5 D. C. Warren, P. O. Box 81, New York 428 Park Bldg., Pitts Hartford, Conn ada, $8.50; Foreign, $12.00 a vear —_, RON Contents FEBRUARY 16, 1939 Efficiency Has Some Disadvantages Titanium and Vanadium Manganese Steel Perchloric Acid Composite Plain and Alloy Steels Carbon Arc Process Advances Presses and Sheet Metal Forming Machinery Night Blindness vs. Safety and Efficiency the Assembly Line Washington News THE NEWS BRIEF Statistics Metal-Working Activity Rate Activity Capital Goods Weekly Ingot Operating Rate Plant Expansion and Equipment Buying Just Between Two Products Advertised Index Advertisers Copyright 1939 by Chilton Company (Ine.) 102 112 115 138 e 9 ‘ Wire for Quick Stock Shi When man's hurry for steel, gets quick action Ryerson. gets steel that has uniform machining and fabricating qualities, that time will lost the shop. gets this steel additional cost. Ryerson CERTIFIED Steels include all kinds— from Open Hearth Carbon Bars highly pol- ished Stainless—Shafting having the qualities most desirable the par- ticular type steel. More than 10,000 sizes and kinds are stock for Shipment. Spe- cial order and dispatch systems—experienced steel men with modern equipment and every shipping facility are your assurance against de- lay. When you need steel, any kind, phone, wire write the nearest Ryerson Steel-Service plant and get prompt shipment uniform high qual- ity steel certified Ryerson. Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. 24—THE IRON AGE, February 16, 1939 ESTABLISHED ... THE IRON AGE ... FEBRUARY 16, 1939 Vol. 143, No. Efficiency Has Some Disadvantages WEEK ago the train which was traveling was stuck, temporarily, the snow Mid-west blizzard. There was nothing but think and look out the window white and stormy landscape. And watch occasional horse and sleigh making progress while were standing still. That naturally led train thought—no pun intended—about improve- ment and efficiency. Here was this streamlined example twentieth century engineering stuck fast, while the relic the and days was still moving toward its destination. And, the evolution transportation, first came the team oxen and the stone boat. Quite improvement was when somebody discovered wheels and had the horse and wagon. And then steam trains. And then airplanes. Each step added its quota speed, comfort and efficiency. Quite way from two miles hour the plane's 200. But let blizzard come along and what happens? Operativity seems run reverse order evolution. the storm severe enough, down come the planes, while the trains are still running. Some more storm intensity and the trains stop, but the horse and wagon equivalents still move. More yet and even they may stop, but you can probably thumb ride via oxteam and sled. times with refinement industrial equipment. Break roll one stand continuous mill and you shut down the whole mill for time. Let something get out order with assembly conveyor line and you will have several hundred people idle. The greater the refinement and intricacy me- chanical organization, the more the trouble when conditions become abnormal and the unexpected happens. industrial engineering, weigh these things and choose refinement spite its drawbacks because its efficiency. But this only because have skilled maintenance forces ready and able repair breakdown. did not have them, industry could not afford this highly organized mechanical efficiency. would too hazardous. So, too, government. Perhaps must admit that the streamlined, mod- ernized, totalitarian autocracies are more efficient than our old-fashioned horse and buggy constitutional democracy. But boy, boy! None them have repair gang. And what will happen them case cobble? y wis, ity. 4 Here Inland’s modern mills and sheet finishing de- partments the ductility and temper iron and sheets and strip undergo profound changes. Here many difficult forming deep drawing prob- lems are solved. They are being solved for Inland customers every day. They can solved for you. Here the workability required for the deep drawing washing machine tub bullet-type automobile fender, the stiffness required door panel are bred into Inland sheets and strip heat treatment. Cut Down Spoilage Costs Spoilage prevented knowing your exact re- quirements. For example, one manufacturer had resorted spot annealing with blow torch prevent breakage when the edge deep-drawn receptacle was turned down later operation. Since using Inland sheets specially annealed for his purpose, this operation has been entirely eliminated considerable saving and there has been practically spoilage from the second forming operation. Don’t Overlook Problem His problem was solved through the call In- land mecallurgist his plant. The economy was unexpected. Such opportunity may exist your plant, too. Inland metallurgist will gladly check the possibility with you your shop men. There cost obligation for his service. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS South Dearborn Street, CHICAGO District Offices: DETROIT KEE ST.LOUIS rawn nated been ming In- men. investigate the comparative effects titanium and vanadium wrought pearlitic manganese steel series small heats this low carbon content was made basic-lined arc furnace and treated with one both these al- loying elements. the titanium steels was added the ladle, while the ferrovanadium used for the vanadium steels was added some heats the ladle and others the furnace. aluminum such was used any these heats. The recov- ery vanadium was always over per cent, while that titanium was generally about per cent. Two kinds ferrotitanium were used, per cent alloy containing per cent silicon and less than per cent aluminum for the smaller additions, and per cent alloy containing about per cent silicon and per cent aluminum for the larger additions. Both were low carbon alloys. The steel was poured into in- gots, which were forged into 7¢-in. round bars for heat-treatment, ma- chining and testing. Chemical and some details the treatment the ingots are given Table None the steels contained over 0.018 per cent phosphorus should noted Table that steels Effect Titanium and Vanadium Forged Pearlitic Manganese Steel ° ° ° GEORGE COMSTOCK Metallurgist, Titanium Alloy Co. ° ° one seven contain 1.70 1.83 per imens cooled suitable rates devel- cent manganese, and steels ferrite network. The heat treat- contain 1.56 1.69 per cent manga- ments included normalizing for two nese, the carbon contents being all hours 1650, 1750, 1850 and 1950 deg. nearly alike. and normalizing, quenching and The properties these steels were tempering three hours 600 deg. F., investigated means tensile tests, two hours 800 deg. F., one hour Izod impact tests, and grain size de- 1000 deg. and one hour 1200 deg. terminations. The tensile tests were respectively. The steels carried out duplicate, and the im- quenched were held two hours 1650 pact tests quadruplicate. The grain deg. for normalizing, and one hour size measurements were made spec- 1600 deg. before quenching TABLE Analyses the Steels Investigated, and Alloying Methods Analysis Ingot —— — 0.23 1.79 0.26 0.25 0.37 0.029 0.21 0.32 0.102 0.26 1.71 0.32 0.147 0.26 1.70 0.42 0.08 0.21 1.78 0.35 0.14 0.21 1.76 0.28 0.22 8 0.25 1.59 0.36 0.24 1.64 0.21 0.020 0.26 1.63 0.54 0.042 0.22 1.59 0.25 0.096 0.24 1.56 0.13 0.10 0.26 1.69 0.28 0.14 0.25 1.69 0.35 0.039 0.17 0.24 1.65 0.33 0.192 0.19 16 0.25 1.66 0.27 0.30 Remarks titanium vanadium. per cent FeTi added ladle. per cent FeTi added ladle. per cent FeTi added ladle. FeV added furnace. FeV added furnace. FeV added ladle. titanium vanadium. per cent FeTi added ladle. per cent FeTi added ladle. per cent FeTi added ladle. FeV added ladle. FeV added ladle. FeV furnace, per cent FeTi ladle. FeV furnace, per cent FeTi ladle. FeV added ladle. THE IRON AGE, February 16, 1939—27 wv Sal } f | . 2, 3 TITANIUM 0-0.22% VANADIUM Yield point, per Elongation, per cent Impact 1650 1950 1650 1850 Normalizing temperature, deg. IG. physical properties nor- malized titanium and normalized vanadium steels, listed Table one seven inclusive. Carbon, 0.26 per cent; manganese, 1.83 per cent. Tensile strength, per sq.in. Yield point, sq.in. 28—THE IRON AGE, February 16, 1939 0-0.147% TITANIUM 0-0.22% VANADIUM Tempering temperature, deg. 2—Quenched and tempered titanium and vanadium steels, listed Table one seven inclusive. Carbon, 0.21 0.26; manganese, 1.83. These data show the variation physical properties the tempering temperature changes. 220,000 | | 100,000 5 ? a 4 — TITANIUM VANADIUM 8 & foal i=) al 1850 1950 1750 1850 Normalizing temperature, deg. IG. 3—Variation physical properties nor- malized titanium and vanadium steels, listed cal Mn, 1.56 1.69 per cent. 1950 Tensile strength, sq.in Yield point, per sq.in 0-0.096 TITANIUM 0.14% VANADIUM 220,000 200,000 & a © E longation, per cent Impact resistance 600 800 1000 600 800 1000 1200 Tempering temperature, deg. IG. 4—Variation physical properties with tem- pering temperature quenched and tempered titanium and vanadium steels, listed Table inclusive. Carbon, 0.22 0.26; Mn, 1.56 1.69. THE IRON AGE, February 16, 1939—29 180,000 \ ~ 160,000 © 60 = i 30 // | 30 a | | 2 9 /0 } E-20 54 = 20 Sian = 150000 n e str Tens 220,000 140,000 130,000 Tensile strength Yield point, per Yield point, per > Reduction area,per cent Elongation, per cent Impact resistance Elongation, per cent uw ao 1850 1950 1650 1950 Normalizing deg. IG. 5—Variation physical properties with nor- physical properties with tem- malizing temperature normalized vanadium, pering temperature quenched and tempered and normalized vanadium-titanium steels, listed vanadium and vanadium-titanium steels, listed per cent; Mn, 1.65 1.69. Mn, 1.65 1.69 per cent. 30—THE IRON AGE, February 16, 1939 100,000 1650 800 600 800 1000 1200 | water, After tempering the steels were air-cooled. steels normalized, quenched and tempered, low high tempera- ture respectively—are reported the sive. Photomicrographs represen- tative samples etched with nitric acid and magnified 100 diameters are pre- sented illustrate the grain-size data. Some the steels were sorbitic (or martensitic?) when air-cooled nor- malizing, that show the grain size these samples were reheated and slowly cooled, annealed, after test- ing the normalized state. The results this investigation can best appreciated reference the illustrations. Fig. the properties the normalized steels and with various amounts titanium are compared the left side with the un- treated steel No. while the right side the normalized vanadium steels and are compared with the same steel, No. The untreated steel represented both sides the full lines. Thus comparing the relative positions the titanium steel curves the left, with the vanadium steel curves the right, both referred the same untreated steel curve, readily seen that the vanadium steels showed, general, higher strength and vield point, but lower elongation, re- duction area, and impact resistance than the titanium steels. grain size, however, there was but little differ- ence, both titanium and vanadium giv- ing finer grain after high temperature normalizing than was found the un- treated steel similarly heated. Fig. comparisons are shown the same way, between the same steels, but the quenched and tempered con- dition. Here again the titanium steels are shown below the vanadium steels strength and yield point, but above them ductility and impact re- sistance. The relations shown here between the treated steels the quenched and tempered condition are not the same, however, the normalized condition. the quenched and tempered condition the titanium steels were about equal the untreated steel tensile strength, and superior yield point (ex- cept when tempered 1200 deg. F.), well ductility and impact resistance; and the vanadium steels were superior the untreated steel every respect, except impact resis- tance after tempering the higher temperatures. Fig. similar Fig. but shows results the steels inclusive, cross-sections forged steels with 1.70 1.83 per cent manganese, etched with nitric acid and magnified 100 di- ameters. Steel No. untreated, nor- malized 1750 deg. F., grain size 0.102 per cent ti- tanium, normalized 1750 deg. F., Steel No. 0.029 per cent titanium, normalized 1950 deg. F., grain size 0.08 per cent vana- dium, normalized 1850 deg. F., grain size half sor- bitic. Typical cross sections forged steels with 1.56 1.67 per cent manganese, etched with nitric acid and magnified di- ameters. Steel No. untreated, normal- ized 1750 deg. F., with some sorbite. Steel No. 12, 0.10 ized 1750 deg. F., Steel No. titanium, normal- ized 1850 deg. F., Steel No. 13, 0.14 per cent vanadium, normalized 1850 deg. F., grain size re ¥ a3 A THE IRON AGE, February 16, ° ° ° Siok > which were slightly lower manga nese. The same general relation be- tween the titanium and vanadium except that the lower-manganese steels Fig. titanium seen have been much more effective than vanadium preventing grain-coars- ening high temperature. The high silicon content heat No. (0.54 per cent given Table should recalled connection with Fig. this undoubtedly accounts for the com- paratively low ductility and impact resistance this particular titanium steel. general, however, evi- dent from Fig. the same from Fig. that vanadium increased the strength and yield point while titanium did not, and that titanium produced greater improvement the ductility and impact resistance these normal- ized steels than vanadium did. ing the properties quenched and tempered steels, these being the same steels that formed the subject Fig. points are missing from many the curves Fig. because there was not sufficient sound steel some the ingots enable the full number tests made. Enough data were obtained, however, check the conclusion drawn from Fig. that strength and yield point, but lower ductility and impact value than titani- steels just did the normalized steels. Figs. and give similar data the manganese-vanadium steels inclusive, with and without titan- ium. The vanadium steels without ti- tanium are represented here the The left-hand halves full-line curves. these graphs indicate that adding titanium steel with about 0.15 per cent vanadium intensified the strengthening and embrittling effect vanadium, especially the normal- ized samples, possibly thoroughly deoxidizing all the residual vanadium the steel, that its maximum influ- ence alloying element was effec- tive. stabilizing influence titan- ium the grain size high tempera- ture also evident Fig. for steel No. compared No. without titanium. The right-hand halves Figs. and show that except for strength and yield point after normal- izing, vanadium high 0.3 per cent was more effective the properties than only 0.19 per cent each vanadium and titanium, which are less expensive. Photomicrographs showing typical microstructures these steels are sub- mitted Figs. and These are intended illustrate the grain-size variations shown Figs. and Summary (1) Vanadium shown these results alloying element which has hardening effect forged pearlitic manganese steel, usually in- creasing the strength and sometimes reducing the ductility and impact re- sistance. Titanium, the other hand, has softening effect, generally de- creasing the strength, but giving de- cidedly higher ductility and impact re- sistance. (2) The beneficial effect titanium the ductility and impact resistance consistently greater than that vanadium; and forged pearlitic man- ganese steels with titanium are more Newport Rolling Mill Co., Newport, Ky., has designed the new Globe rain drain galvanized roofing sheets offset rusting out from the under side because moisture drawn between sheets side and end laps due capillary attraction. the Globe sheets, seepage between sheets overlap base courses prevented interposing airlock the path the water. Water that may blown under sheets side laps quickly conducted the eaves the rain drain channel rolled into the outer crimp. Other features identified the illustration are: improved triple dome crimp (2); nail seat (4) rolled into the airlock bead; snug fit edge (5) bent downward in. form pressure contact with the under sheet; self-alining ridge (6), continuation the air lock bead; and the almost vertical supporting leg (7) under the overlapping crimp pro- vide greater rigidity for nailing. 32—THE IRON AGE, February 16, 1939 ductile and more resistant impact than similar steels with vanadium. (3) Both titanium and vanadium show tendency reduce the grain- size, and often maintain fine grain normalizing temperatures high 1950 deg. F.; but titanium gen- eral more effective this way than vanadium. these steels with around 1.7 per cent manganese, required more than 0.02 per cent residual titan- ium give reasonable stability grain size the higher temperatures, 0.03 0.10 per cent being satisfactory but considerably more vanadium was needed for the same purpose, even 0.10 per cent one steel failing prevent coarsening 1750 deg. (4) When titanium was added with vanadium, the effect the latter alloy was intensified. (5) With titanium for part high vanadium addition, such 0.3 per cent, the properties general- were not impaired. Thus there opportunity for economy prac- tice through adding titanium with decreased amount vanadium vanadium alloy steels. Acknowledgments The effective cooperation many the author’s associates the staff the Titanium Alloy Mfg. Co. gratefully acknowledged connection with the work reported above. Special credit due Mr. Wolf for melting and forging the steels, and Mr. Yocco for most the heat- treatments, testing and photomicro- graphs. The helpful suggestions Dr. Morris Cohen Massachusetts Insti- tute Technology regarding the ar- rangement the data and the report were also appreciated. generally acknowledged that none the evolution methods, de- concentrated boiling tempera- ture, has been found determining sulphur certain alloy steels, for instance, high speed steels, Cr-Mo Cr-Ti steels, etc. Inthesecond edition Special Steels! there was published different evolu- tion method which the total sulphur high speed and some steels and certain the sulphates can evolved about 1000 deg. Over finely divided drillings slow stream the case sulphates the reaction can mention several other sulphates, the following similar reactions take place above red heat with The H,S caught ammoniacal solution cadmium chloride and the determination finished the usual way with iodine and This method requires about three four hours and accurate for the usual 18-4-1 high speed steels with without cobalt and some molybdenum. number lower alloy steels form protective films under the conditions temperature and reducing atmos- phere just described. For such steels the evolution 1000 deg. with not complete. may that, the still higher furnace tempera- tures now available, these protective films can penetrated. The phosphor gave 0.064 0.068 per cent the 1“Chemical Analysis Special Steels,” Morris Johnson, 4th edition. Part MORRIS JOHNSON Chief Chemist, Crucible Steel America, Park Works ° ° ° evolution method, whereas the official content was 0.060 per cent The bronze was the molten state, course, during the evolution the interesting note that the iodine solution can standardized the H.S evolved from the the two sections this series articles, published Oct. and Dec. 29, the au- thor described detail the use perchloric acid the deter- mination manganese practically every alloy steel. this the third section, the perchloric acid procedure for the determination sul- phur steel, coal and coke described step step. Previous the time when was found great advantage get- ting the total sulphur highly alloyed steels, the following procedure stood the test through the years: Standard Method The old standard method deter- mining sulphur gravimetrically follows: Decompose gm. drillings red mixture 100 ml. each concentrated plus Add the mixture slowly, and heat until ac- tion ceases. Then add gm. aiter which evaporate dry- ness. not bake. Redissolve heat- ing with 100 ml. concentrated HCl and evaporate dry, and then redissolve ml. concentrated and evapo- rate ml. Dilute with 100 ml. Heat and filter off insolubles and then wash with part and parts H,O. Dilute the filtrate and washings 400 ml. with H,O and heat boiling. The hot solution should not smell sharply HCl, but have sweetish odor. Add once 100 fil- tered, saturated, boiling solution BaSO,. Stir thoroughly and let stand over night, after which filter out the and wash with cold H,O, which 500 ml. H,O, until washings test free iron. Ignite the BaSO, free the paper and treat the ash with few drops and 1:7 Evapo- rate dryness, then ignite and weigh Deduct blanks including all chemicals and operations. can also used this method. Total Sulphur HCIO, The determination total sulphur steels the (perchloric acid) method requires special ap- paratus such high temperature fur- naces and tapered end refractory tubes and trains. This has dulled the inter- est and lessened the inducement further develop the evolu- tion method 1000 deg. higher, previously referred having con- siderable merit. Further, the wide application the perchloric method all sorts carbides, and its rapidity and accuracy make indispensable reagent. The writer has found the following process give accurate sulphur percentages for all alloyed steels yet THE IRON AGE, February a or ti- encountered, and some iron ores and complicated alloys iron such high nickel-high copper-cast iron con- taining chromium. probably the most rapid umpire method known. ml. beaker. Add slowly red mixture ml. each concentrated HCl and concentrated Heat until action ceases, and then follow with gm. anhydrous This essential detail, low results are gotten when Then pour ml. per cent C.P. Boil down deep red solu- tion and heavy fumes, red salts present. After cooling, dilute with 200 ml. Add gm. sulphur-free granulated and concentrated HCl. Run blanks the chemicals and all opera- tions. The zinc the blanks dissolves slowly, tests and blanks are all brought slow boil until the zinc dissolved. Add some ashless paper through 12.5-cm. rapid ashless papers. Wash times with 1:20 Dilute the filtrate and washings 400 then heat boiling and add 100 hot filtered, saturated, water solu- tion Stir this for ten minutes and let settle for one two hours, depending whether the sul- phur the order 0.02 0.050 per cent higher. Or, the precipi- tate may settle until the next day. The precipitates are filtered after the time interval, necessary, through 12.5- em. rapid double ashless papers. Wash once with drops 1:1 diluted 500 then wash five times with cold distilled water and on. BaSO, distinctly soluble stronger acid and there need more acid wash. least washings are rec- ommended free the papers all traces barium salts. Ignite ash low heat weighed platinum crucible, and then moisten with few drops 1:7 and HF. Evapo- rate dry, and ignite red heat BaSO,. Figure the percentage sulphur multiplying the BaSO, weight parts gram 13.73 and divide the weight taken. Four sam- ples, i.e., two tests and two blanks, can put through the test cycle seven hours, that within the same turn. The washings are kept separate from the main filtrate and tested the addition ml. solu- tion. sure inside walls hood and flues are washed frecuently prevent ac- cumulations mixture perchloric fumes, soot dust. Otherwise explo- sion likely. Analyzing Coal and Coke,” edition 1929. IRON AGE, February 16, 1939 The values shown Table were obtained the old standard method and the new perchloric acid method. The samples include plain steel, free- machining stainless, cast iron, special high nickel-high copper cast iron, No. 115 Bureau standard containing chromium, and Ni-Resist. Note how close the results check. Sulphur Ore Three widely differing iron ores were analyzed the perchloric acid method follows: gm. were ground the fineness wheat flour. This was then digested, until there was further action, with red mixture concentrated HNO,, and next treated with gm. Na.CO, ml. concen- per cent. This was then evaporated heavy fumes Water and paper pulp were added and insolubles filtered out. Wash and then finish the sulphur barium sulphate already described for steel. The percentages sulphur found iron ores are shown Table IT. Sulphur Coal and Coke The determination sulphur coal and coke solution the carbon and sulphur with acid potassium permanganate final fuming with perchloric acid, carried out shown the following paragraph. This KMnO, method originated the Park Works April, 1937. First grind the sample the ex- treme fineness wheat flour. Weigh SPECIAL analysis bench such the hood the background down frequently into 800 ml. beakers 0.2 0.3 gm. the sample, and more, for fear Then introduce gm. crystals, and follow with con- centrated Also include gm. per cent reagent grade Run blanks. Boil down heavy fumes with the latter coming out the TABLE Comparing Old and Perchloric Acid Methods Sulphur Determination Old Method, Perchloric, Official Bureau Bureau No. 105....... 0.59 0.59 (about) Cast iron, No. 0.096 0.093 Plain steel, works std. ............ 0.063 0.063 Bureau No. 115, Ni-Cu-Cr 0.034 0.035 Free Machining 18-8 ........ 0.196 High speed steel, Mo, Cr, 0.009 HCI evolution outside laboratory showed 0.008 per cent S.) TABLE Percentages Sulphur Found Ores Various Methods Perchloric, Fusion* Official, Per cent Per cent Per cent 0.032 per cent, 0.030 0.033 0.025 Magnetic ore sample, per cent 0.260 0.256 Hematite, 2.54 per cent SiO. 0.004 trace fusion one-gram sample was fluxed with gm. anhydrous one gram | J | i — | a q & j : | y on er this helps speed perchloric acid determinations. The metallic exhausts are excellent for maximum safety; the woodwork, however, should washed reduce danger explosions. heaker with the cover for least min. order dissolve all the coal (or coke) particles. Cool and dissolve the excess manganese ox- ide with ml. concentrated with heat. When clear, take slight fumes and then dilute 550 ml. All samples that have been heated have shown only pure white insolubles this stage. There has been sug- gestion undissolved carbon the coal coke thus far tried. Add paper pulp and filter out the insolubles, and wash them times with one part concentrated parts Heat the filtrate and washings boiling and likewise heat 100 ml. Add the latter and TABLE Sulphur Determination and Coke Various Methods Bureau Park Plant Park Plant Park Plant, Mines Laboratory Laboratory, New Perehloric Experiment Eschko Fusion with Solution Station, Method, Method Sample Per Per cent Per cent Per Cent 11256 (coal) 1.03 1.02-1.05 0.66 0.68-0.68 0.68-0.68 0.68-0.67 15254 (coke) 0.93 0.94-0.95 0.96-0.93 1.23 1.27 885 (coke) 0.74-0.75 0.75-0.737 886 (coke) 0.64-0.65 0.66-0.65 0.638-0.636 Coal 4.85-4.82 5.04 Coal resampled 1.77 Coal XX, resampled 4.99-4.97 SUPPLEMENT TABLE Old Standard Official Method New Method Per cent Per cent Per cent Steel Samples Sulphur Park Lab Sulphur Bureau No. 0.083 0.082 0.080 Bureau, No. 105 High 0.590 0.603-0.604 0.596 stir thoroughly. Let the settle for two hours, longer desired. Wash the BaSO, only with the slight- est acid solution 1:1 500 ml. H,O) otherwise the washings are kept separate and tested with ml. BaCl, quite precipitation BaSO, may gotten the wash- ings. Without and even using lower results than the accepted per- centages were obtained. success was attained including the the case quite high percentages, higher results were got- ten than the Eschka method ment Commerce. using this new procedure for standard steels, the ac- cepted figures were verified. fu- sion 0.4 0.5 gm. the coal Armco iron crucibles, with mixture dry gm. plus gm. Na,O, acidulating the fusions with and evaporating dryness, dis- solving and filtering out white solubles and precipitation the sul phur BaCl,, the highest results were confirmed, after deducting blanks. See the tabulation Table Routine Procedure summary the technique, consider the following: (1) Weigh into 800 ml. beakers 0.2 and 0.3 gm. the finely powdered coal, ground agate mortar the fineness wheat flour, near that mesh possible. Larger quantities may cause explosion. (2) Next put into the beakers gm. Always add the this order each test. (3) Then add ml. concen- trated HNO,. Heat for min. (4) Add the beakers gm. (6) Boil heavy fumes and fume heavily for min. (7) Heat with ml. 1.20 sp. gr. dissolve all manganese oxide. Dilute once with 550 ml. H,O prevent salting out the crystals Promptly filter out Wash filter times with 1:20 and bring the filtrate and washings boil. Add 100 ml. hot solution then stir thoroughly and fin- ish using very dilute wash ml. 1:1 500 ml. H,O). prove that results were not being exaggerated, high and low sulphur steels were analyzed exactly the same way and correct percentages were obtained, shown Table THE IRON AGE, 16, Yes ne Composites Plain and Alloy Steels actuating motive use composite metals usually one reducing the initial cost the cost use. Thus, copper clad steel wire for railway signal bonds lasts ten times long pure copper bonds the same initial cost, because the resistance the steel Nickel used for making vessels which handle food products costs about one half much solid nickel plate for the The composite has greater strength and, since only one side can possibly come contact with the food, serves the purpose exactly well. veloped recent have found many uses. The per cent chromium, per cent nickel specification with additions possibly molybdenum, columbium, titanium, comprise present the most popular group stainless steels. Use these almost noble metals inhibited the high price for which they must sold. $580 per base price, 18-8 costs roughly times much carbon steel. Economies Composite Metals about half the low-carbon steel with properly ap- plied cladding 18-8 would serve the purpose just well solid stainless. The price might half much for the composite material for the solid stainless. With 1937 production 75,851 tons finished stainless and heat-resisting alloys, having aggre- gate value about $60,000,000, the desirability composite material obvious. While the advantages composites low-carbon steel and very expen- sive metals are striking, the economies composite metals are means restricted such cases. Thus, one the serious problems been encountered the design and construction welded steel machin- erv has been lack low cost com- IRON AGE, February 16, 1939 posite metals. Machined surtaces low and medium-carbon steel are ex- pensive compared with machine work steel having 0.40 per cent carbon, and fact that lubrication difficult and wear unsatisfactory for rapidly moving parts made low- arbon steel. Building aces manual even automatic welding machines is, cases, prohibitively the other hand, the parts are made steel having the machining and wearing qualities 0.40 per cent car- bon more, becomes necessary preheat the machinery part welding operation prevent from cooling rapidly and cracking.. G Composite Gear Blanks tion the building welded stee! machinery parts the problem making welded steel gear blanks. The rim needs 0.40 per cent carbon steel above have the gear tooth cutting operation successful. The mainder the gear blank medium carbon steel. The job handling the welded type gear blank and welding while hot that most manufacturers pre- fer buy cast steel blanks. line bar stock were available from the steel mills with say per cent the thickness 0.40 0.50 per cent carbon and the remainder the 0.15 0.25 per cent range, most manufacturers would make their own gear blanks by. welding. The rim would formed hot with the higher carbon the outside. The assembly the welded steel gear-blank could then made welding the low- carbon side without preheating. The same composite would useful also welded steel machinery—for guides. ROBERT KINKEAD the new method making com- posite metals here described, car- bon arc welding equipment em- ployed for forming stainless other steel coating the surface heated low-carbon steel ingot slab. The composite thus produced then rolled down clad material ranging thickness from in. No. gage. The advantages composite metals are not confined combinations low-carbon steel and ways planers, and many other places. Need for New Method Making When composite metals are fabricated, their usefulness always function the quality the bond between the component parts the composite. Unless the bond perfect, the metals separate fabrication. Thus, plating alone used after the metal has been formed and all the cold work completed it. The bond one adhesion, not cohesion weld, get cohesion plated composite must hot rolled. further necessity that the com posite have uniform complete bond between the compo nents. Even though per cent the area contact components perfectly bonded cohesion, but the remaining per cent area held only adhesion, the composite will commercially unacceptable. Failure will occur when the formed with the surface component show blistering service where the composite material subjected heat. skillet made composite | | eee Consulting Engineer, Welding, Cleveland expensive metals but apply also composites such medium carbon and plain steels, which might used advantage the construction weld-fabricated machinery. The ar- ticle from paper that received the third Grand Award the recent $200,000 Program sponsored the James Lincoln Arc Welding Foun- dation, Cleveland, which savings $1,600,000,000 were shown available wider application arc welding. carbon steel and stainless for the inside serves the purpose well the bond perfect and complete. But the bond not perfect and complete the stainless will blister has about two and one half times the expansion and contrac tion carbon steel. The point well illustrated also the case stainless oil refinery XPERIMENTAL equipment used for making com- posite metals carbon arc weld- ing. The welding head mounted the tool-slide planer, and oscillated trans- versely cam arrangement. While they give lite consideration their cost, they fail blistering between welds long before the lining itself appreciably corroded. low cost composite metal meeting these requirements has heretofore been available, spite these obvious needs. The requirement that the bond composite metals good for 100 per cent the area contact the first and most important The second need that the composite shall made low cost methods that its manufacture and sale carried out yield profit the maker. Desirable Make Composite Steel Producing Plant Necessity for making the compo- sites low cost immediately indicates that the metal should operated early the basic process manu- facture possible. Steel made, rolled and processed the most handle mass production basis and produce cost which pro motes its universal use. The con clusion cannot escaped that the time make the composite while the metal the ingot slab or. some cases, the billet form. the metal made composite here, goes through all the subsequent rolling and processing equipment which can handle high speed and with low cost. The contrasting cases making nickel-clad steel and making electro- plated steel, which subsequently hot rolled, illustrates the point. Nickel-clad steel made rolling together solid nickel slabs and steel slabs. thick nickel slab slab. Thus, working sq. ft. steel in. thick, sq. ft. per cent nickel clad steel obtained when rolled down in. thick- ness. the other hand, plating 0.013 in. copper 0.125 in. thick steel for subsequent hot rolling would entirely prohibitive cost, because times the area would have operated on. The process and equipment herein- after described are designed work ingots, slabs, billets the steel oO vs producing plant and further proc essed existing equipment. Manufacture Carbon Arc Welding* Considering ingot low-carbon steel, all that needed make composite add the necessary al- loying elements the metal the surface get the desired chemical analysis. This may readily ac- complished carbon welding. would roundabout and rela- tively expensive process coat the surface the ingot with the alloy desired the form metal wire rod using the metal electrode arc welding process. the case car- bon welding, the making surface only necessitates adding fer- rochrome and nickel with alloying element cost about 8c. per 18-8 produced. Making 18-8 sur- face depositing 18-8 rod and the metallic arc would volve cost 50c. 60c. per for the stainless steel rod. latter case, the alloy made and re- duced rod form suitable for weld- ing and heavy costs are involved. the carbon arc method, the stainless steel made directly the ingot using the ingot metal itself base. Experimental production compos- ite metals carbon welding has been carried out over period two years. avoid excessive cost experimental apparatus, work has been done slabs where the depth which the surface alloying ex- tended could from in. The experimental equipment used shown one the accompanying *Patents are pending process de- scribed. IRON AGE, February 1939 OMPLETELY processed clad gage sheets: (At left) Structure 18-8 clad sheet. The dark bond may appear separation the two metals, but such not the case. (Center) Structure 18-8 clad sheet. (At right) Microstructure per chromium clad sheet. Clad structure (top) consists ferrite and carbides and typical regular per cent Cr. Structure the plain carbon base metal normal. The bond consists small ferrite grains with large number carbides. all cases the 100X. Lincoln Tornado car- bon are head mounted the tool carriage planer. Motor and cam arrangement provided oscilliate the head transversely the direction travel the planer bed. The cam was designed empirically give uni- form distribution the heat oper- ation that uniform depth pene- tration the alloy was the result Many slabs were sectioned and the penetration measured and rected accordingly. Current for the are circuit was obtained from Lincoln S.A.E. 800-amp. welder for thin alloy surfaces and from special motor-generator for currents 3000 amp. for thick alloy surfaces. The furnace mounted the planer bed provided for preheating the slab and working with the while hot. Adjustable speed pro- vided the planer bed. This experimental making com- posite metals may briefly described follows: The slab (0.04 0.06 per cent carbon, 0.20 0.30 per cent manganese) put the furnace and suitable ground connection made it. The alloy applied shallow pans very thin low carbon steel, which are melted the process. The Typical Analysis Data TABLE 18-8, Per Cent Cladding, in. Slab Speed Current Arc Preheat (in per Amp. Voltage 0.08 17.52 8.52 800 deg. 1.55 1800 0.08 18.60 8.23 800 deg. 1.61 1800 0.06 18.36 8.92 800 deg. 1.52 1800 0.07 17.60 8.07 800 deg. 1800 TABLE 18-8, Molybdenum Speed (in. 0.06 18.21 9.34 2.70 1.28 800 deg. 1.55 1800 0.06 18.20 9.34 2.40 1.16 800 deg. 1.51 1800 0.07 19.86 10.68 3.10 1.38 800 deg. 1.52 1800 0.08 19.22 9.41 2.60 1.90 800 deg. 1.50 1800 | : W clad gage sheets: left) Microstructure per cent chromium clad. Clad consists ferrite and carbides, and with excep- tion the laminated condition, comparable solid per cent material. Structure base metal normal. (Center) this per cent chromium clad the structure the clad (top) typical that per cent Cr. The bond structureless. Grain growth the O-H steel confined the zone next the bond. (At Semi-processed 18-8 ciad hot rolled plate, showing greater detail the structure where the metals join. Magnification this 750X; the others are 100X. bottom the pan covered with the the alloy and slag the proper lo- correct amount alloy. making cation. excess slag applied 18-8, ferrochrome the low-carbon around the margin the pans keep specification broken down mesh the metal from flowing off the slab used, together with nickel shot. when the operation progress. Molybdenum, columbium, manganese may added, depending the grade alloy wanted. The slab heated temperature about 800 deg. determined pyrometer with the top the fur- The pan then completely filled nace covered. The carbon weld- with slag, the height the pan being ing operation started after the that when level full the cover has been partially removed and right amount present. This slag proceeds from one end the alloyed waste slag from electric furnace surface the other. in. oscilla- which 18-8 has been made, together tion the arc and in. travel was with sand and calcium fluoride. The found suitable for obtaining the speci- slab now heated the furnace with mens required for testing the compos- TABLE Chromium Speed Current Arc Preheat (in per min.) Amp. Voltage 0.09 11.97 800 deg. 0.08 12.59 800 deg. 1.6 1800 Chromium 0.06 17.28 800 deg. 1.70 1800 Chromium 0.12 25.08 800 deg. 1.68 1800 0.09 29.60 800 deg. 1.71 1800 a * ite material throughout the complete rolling and processing and final test ing. in. thick slabs 1800 volts across the arc, 1.6 per min. planer bed travel were found suitable Under these conditions, the metal alloyed would stay molten from three- fourths the total length the travel, depending the alloy being made. This was found very important matter. After sectioning many alloyed slabs, was shown con clusively that failure obtaining perfect bond over 100 per cent the area contact was ever encoun tered without striking evidence being visible the surface. Thus the process was developed the point which there could never any uncertainty relative this most important consideration. Any unusual condition resulting clusions immediately evident the surface the alloyed metal. After the alloying operation, the slab removed from the furnace and cooled. The slag then easily re- moved. Subsequent operations the making the finished product occur about follows: The surface the alloy given light grind remove scale and un- even spots. The slab then put the heating furnace preparatory rolling. the case the test slabs. the hot rolling was first done re- duce and spread the alloy. The long dimension went into the rolls parallel the axis the rolls. Rolling was done two stages—first, down about in. thickness and allowed cool. Later the material was hot rolled down in., 3/16 in., THE IRON AGE, : gage. material was then annealed and pickled, and some cases cold reduced down low No. gage. serious difficulty was encountered rolling operations. Results Chemical Analysis typical chemical analysis the alloy component the composites made the methods given herewith. fairly obvious that the process controllable pro- duce alloys the form composites specifications. While the experimental apparatus was crude and difficult control, every cause variation was explored and the difficulties corrected the design the commercial production equip- ment. Physical Nature Bond Photomicrographs herewith show the nature the bond between low- carbon steel and 18-8, well the condition the metals forming the composite. The illustration showing the carbon steel etched away from the stainless shows the most desirable physical contour the will noted from the actual specimen furnished that the bond does not occur smooth plane. apt analogy the case two optical flats wrung together. They cannot tension normal the bonded sur- faces, but may slipped apart. The non-planar bond this composite metal entirely free from this defect bonding. The illustration showing sumably martensitic structure very thin layer the bond charac- teristic the process. layer the bond does not affect the physical behavior shown the bent and severely deformed material. Many tests have been carried out at- tempt break the composite metals apart the bond. None successful. The most severe test the stainless carbon steel composite the blister test where local heat applied the stainless side with oxy-acetylene blowpipe. The slightest bond will result blister where the metal heated. such defects have been found. The reason for this perfect score simple. Had something gone wrong the alloying operation, would have been immediately discovered and the defect repaired metal arc weld- ing, using stainless rod before the metal was rolled. There are de- fects the rolled metal for the reason IRON AGE, February 16, 1939 ICROSTRUCTURE completely process- 18-8 clad steel, gage sheet. Heavy grain boundaries clad near bond indicate carbide precipitation. Structure base metal normal. 100X. that would not have been rolled had there been any defects present. Fur- ther, the case 18-8 the marten- sitic structure the bond stronger than either the normal stainless the carbon steel. would not expected that the stronger metal would break before the weaker. Costs The factors which total cost making composite metal this method are ones with which steel mills are accustomed deal that cost the product may easily Thus, the alloy cost for the per cent chromium, per cent nickel metal roughly 8c. per One 2500 amp. carbon are will make about the alloy the sur- face preheated slab per minute. The power taken from the line about 1.2 kwhr. per alloy made. Carbon electrodes, slag, are al- most negligible factor the cost. Cost preheating slabs may vary from $2.00 $5.00 per ton. The out-of-pocket cost material, heat, power and labor, obtain per cent cladding 18-8 low-car- bon steel and hot rolling the order $104.00 per ton composite. The cost making the alloy the surface the slab approximately per lb. for per cent chromium and per cent nickel. the total per for this alloy, approxi- mately 8c. for ferrochrome and nickel shot; the remainder being the cost operating the process. The 18-8 metal being the most expensive ordinarily used represents the highest costs. Costs processing the composite beyond hot rolling depend great composite metal made show that bond does q a = ~ 3 with electric furnace and trained steel. Since both the thickness the slab worked and the thickness the alloy applied may varied, the process adaptable the production composite metals having ICROSTRUCTURE thin coating alloy. Perfection 18-8 clad steel, . . chromium one both sides. tin per ton high grade product but seems quite likely that the same steel with per ton per cent chromium the surface would offer longer life and better sistance. The same conditions apply com- parison with galvanized steel. With out-of-pocket cost applying per cent chromium the order 10c. per and extra cost for grit blasting belt grinding before pick- ling where the cladding applied only one side, the cost the com- posite stili comparable the cost tin plate. blasting, cold reduction, polishing other operations may carried out usual costs for these operations. Adaptability Process particular feature the process that may used steel pro- ducing plant which not equipped Rust-Ban Protects Steel During Storage and Transit low-carbon steel and 18-8 deformed not fail under any conditions. NEW line products which in- hibit rust and corrosion has been announced the Standard Oil Co. New and its Esso Marketers affiliates who will market them under the trade name, Rust-Ban. These new coatings are said not only contain various conventional petroleum ingre- dients which themselves act pro- tection against rust, but they also em- ploy new and special rust inhibitor which greatly increases tion. The effectiveness these products has already been accelerated laboratory tests, three which are unusually significant: the humidifier test, the water spray test and the salt spray test. Extensive field experience has al- ready been obtained with these new products. The company gives the fol- lowing examples: steel corporation has standardized one type Rust-Ban for coating car axle journals during storage and shipment. continuous strip mill tested this product polished panels rolled strip located within ft. pickling bath. After three weeks the coated panels were still perfect condition. large manufacturer machine tools has chosen the product for protection units ment, while manufacturers razor blades found tageous. One unusual experiment involved sewing machine needles salt spray test. This test had previously been where had been found that five weeks protection the laboratory test needles coated and wrapped was equal approximately five years nor- ma