The Iron Age 1939-04-13: Vol 143 Iss 15

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors F. J. OLIVER W. A. PHAIR G. RICCIARDI Washington Editor MOFFETT Resident District Editors CAMPBELL Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Newark, N. J St. Louis TURNER, JR. Buffalo Owned and Published by CHILTON COMPANY (Incorporated) Editorial and Publication Office Executive Offices Chestnut and 56th 239 West 39th Philadelphia, Pa. New York, OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE, THOMAS KANE, CHARLES BAUR, CARROLL BUZBY, FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations Member Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, 25 cents. Cable Address, “Ironage, N. 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 Se, 239 W. 39th St., New York Robinson 428 Park Bldg., Pitts. D. C. Warren, P. O. Box 81. Hartford, Conn ROBERT BINGHAM ROBERT MCINTOSH Contents APRIL 1939 The Break-Even Point for Employment Ask the Man Who Runs One Flush Riveting Airplane Fuselages Case Studies Cost Reduction New Machine Welds 78-in. Strip Gating and Feeding ...... Leveling Production Peaks and Valleys Boiler Plant Recent Machine Tool Developments Characteristics Hydraulic Drive Transmissions the Assembly Line Washington News ..... THE NEWS BRIEF Rate Activity Capital Goods Weekly Ingot Operating Rate Plant Expansion and Equipment Buying New Industrial Literature Just Between Two Products Advertised Index Advertisers Copyright 1939 Chilton Company 108 126 130 } - | Certified Help Lower Labor Costs Labor costs, rapidly becoming today’s No. consideration, are measure dependent materials. most jobs where steel used, shop costs are the largest and most variable single fac- tor. While the cost steel itself relatively small, the quality plays very important part the control these shop labor costs. hard fabricate—does not work uniformly—has hard spots dull break tools the case alloys, does not respond properly heat treat- Principal products stock for Im- mediate Shipment include—Bars, Structurals, Plates, Iron and Steel Sheets, Tubing, Shafting, Strip Steel, Alloy Steels, Tool Steels, Stainless, Babbitt, Welding Rod, etc. 26—THE IRON AGE, April 13, 1939 ment—then shop labor hours pile and the job ticket shows red. meet this growing need for more uniform, better fabricating steels, Ryerson developed and built stocks CERTIFIED STEELS—steels that represent the highest quality each class and type material. Users are reporting savings time, reduction spoilage and lower labor costs. Perhaps Ryerson Certified Steels can help you reduce costs. Why not try them your next Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. 7 >) f y : ESTABLISHED THE IRON AGE ... APRIL 13, 1939 Vol. 143, No. The Break-Even Point for Employment VERY executive knows about the break-even point for profits. that point vol- ume which the seesaw profit and loss exactly balanced. Add more volume and the profit side the seesaw rises rapidly. Subtract little volume and the profit side dips and the loss side soars the air. critical point for business. Most American concerns are hovering there- abouts the present moment. That means insomnia for the management and night- mare for the stockholders. Profits well losses are greatest, per unit volume, near the break-even point. have seen how works the steel industry. have seen company— many them fact—dip hundreds thousands dollars the red one quarter and emerge many hundreds thousands black the next. Such the magic the break-even point. appears that there similar break-even point for employment American private enterprise. But does not work quite the same way. The downswing the employment seesaw, during depression, recession, whatever name you may have for poor business period, cushioned. cushioned spreading the work, working fewer days per week fewer hours per day, alter- nating shifts. Thus the number unemployed does not increase fast would if, under such circumstances, people were discharged and smaller number kept work full time. one questions the social advantages this policy. spreads wages far possible bad times. But also has dampening effect the upswing. When business begins up, emerge from recession, men are not trans- ferred from the ranks the unemployed the ranks the employed proportion the gain business volume, would necessary the downswing had not been cush- ioned. There slack taken before more people are put the payroll. People who have been working for two days week, for example, begin work four five days. Thus, takes time reach the break-even point where national unemployment be- gins affected business rise. The slack must taken first. have had approximate per cent increase the level business whole the last twelve months. Yet the number unemployed has not decreased perceptibly. That not indictment private enterprise nor should discourage future hopes for private reemployment. simply indication the fact that have not yet reached the break-even point. “Hard steel” more common phrase. But lacks imagination, not also experience, who thinks only steel’s hardness. Today’s stream- lined designs and production economies, too, are made possible steel’s softness, its ease forming. The hardness softness steel sheets merely number qualities that can adjusted your particular needs when Inland metallurgist understands your problems. working you, makes steel work for you better advantage. Inland metallurgist demonstrate the full meaning this fact developing sheet especially suited your purpose. This suggestion may help cut your costs, improve your product, both— without any obligation expense you. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS 2 Dearborn Street, CHICAGO District Offices: DETROIT KANSAS CITY ou, the reasons why today’s automobiles are satisfactory the average user that he, himself, has helped design them. Every major automobile company has some means determining the con- reaction different automo- bile features and uses this information help determine what design im- provements make. This does not mean that automotive engineers are not capable designing machine which, them, the last word. does show, however, that sometimes the designer, the man who knows great deal about this subject, has different ideas from the fellow actually runs the automobile. builders turret lathes, our company has recognized that the oper- ator could tell lot about building turret lathes. For number years system has been maintained whereby these suggestions and complaints were brought the design committee for action. There always existed the question, however, whether the suggestions who were getting were representative sample. often wondered should get more help- ful and more frank suggestions asked for anonymous reply. find out, recently sent ques- tionnaire operators turret lathes. asked them about the operation turret lathe, exactly auto- PHILIP BLISS President, The Warner Swasey Co., Cleveland mobile company might ask the driver about the operation the car. wanted know what they liked and didn’t like about the machine they operated. Extremely interesting and illuminat- ing replies were received. While many the questions had with sub- jects too specific wide in- terest, the significance the replies some questions, seemed us, would value all industrialists. What impressed most about the replies were the quantity and quality the suggestions made these oper- ators. Although some cases there was some difficulty finding words express their thoughts, ordinarily were put good, straightforward English. almost every case, their suggestions were very intelligent ones. They did not ask for impossible things. They knew what they wanted, and they told exactly what that was. course, many the suggestions covered ground that our engineering department has been working over for years, and far know, living man has discovered the com- plete answer the problem. Some new details have been brought up, however, which are worthy serious thought, and our engineering depart- ment working these suggestions. going over the replies, won- dered whether buyers shop ma- chinery talked with the operator about shop problems often enough. was apparent that operator was not fooled gadgets, that features that have selling appeal, but little real value. When new piece machinery proposed, the operator could probably very helpful forecasting whether extra machine features would worth their cost whether standard machine produce just well. would Operators stressed the importance having controls the right place. this respect they are different from automobile drivers. The auto- mobile driver likes his steering wheel, clutch, brake lever, accelerator and gear shift lever all within easy reach. does the machine operator. quite pleased, therefore, when man- ufacturer anticipates his desire and places all operating controls within arm’s reach. THE IRON AGE, April 13, + 1 ° ° ing ted ARS Since ease operation was one the most important points stressed operators, this basic necessity for efficient machine tool construction. all, build machine with great productive ability and then fail allow for the human desire things easily possible, our ma- chine will not produce much should. Now, let see what operator would were buying turret lathe. asked him, the most important requirement buying turret lathe?” The answer receiving first place may surprise you. was accuracy. and ease operation third. While ease operation may uppermost the operator’s mind from his own personal standpoint, ac- curacy—or more specific, the ease with which accuracy obtained the operator the all-im- portant thing from the owner’s stand- point. This significant because shows that operators can and think terms net results. bares their desire solve problem that pres- ent practically every shop, namely, turn out better product. the machine produces accurate work easily, this means that the man will get some personal credit because, after all, accurate work means less trouble succeeding operations and lower cost assembly, well better product. The operator, then, thinks that the owner should look for ma- chine that accurate and stays ac- asked the operators, “Why hard get good results?” Away out first place was the answer, “Not enough tools.” This significant because the an- swer the operators give exactly the same answer would our own company engineers and probably machine tool manufac- turers general. Concerns spend thou- sands dollars for new equipment because has proved that will pay for itself over short period time. they would keep their new and old machines provided with the proper tooling and attachments, they would find additional and very large savings available. The operators understand this situa- tion because they run the machines. They know how much easier and more rapidly job can done the right tools are hand. Asking each operator what needs special job will often show how $50 $100 expenditure will pay for itself out few weeks’ savings. Here again, the operator can help making valu- able suggestions. light this questionnaire—the num- ber years experience the thousand more operators answer- ing the questions. Two and one-half per cent had run turret lathes less than one year, 32.6 per cent one five years, 18.3 per cent six ten years and 46.6 per cent over years. These figures tell their own story. There is, potentially least, short- age trained operators this field. These figures indicate how few men were taken into industry during the worst the depression period. They show that since the depression period not enough new trained. The men who have operated turret lathes over years are probably the best operators the world. have certainly found that age deter- rent first-class workmanship just long physical health remains. After all, however, time does march and every year additional mechanics must trained fill the shoes those who must inevitably lay down their tools. Industry has not adequately trained new men during the past years. This remains problem that must faced some day, when, with better business, shortage workers certain come. The more see skilled machine both our plant and those our customers, the more im- pressed are with them group. The results this questionnaire only served bolster our belief their ability. These men may not aware all the considerations thought the time machine tool pur- chased; but they certainly can con- tribute ideas that will help you make the proper decision. Porcelain Enamels NEW development resulting greatly increased opacity for porcelain enamel finishes has been announced the Ferro Enamel Corp., Cleveland. per cent thinner than that required with the most opaque last year’s porcelain enamels, the opaque enamels have covering power measured opacity equal that the 1938 finishes. Investigations with high-power microscope have shown that per cent opacity reading, which required 246 gm. cover coat enamel per sq. ft. surface only ten years ago, now can obtained with Ultrapaque only gm. per sq. reduction per cent ap- 30—THE IRON AGE, April 13, 1939 Per cent reflectance a Grams per square foot dry weight plication weight. The weight-reflec- tion curves for sheet steel cover coats, shown the accompanying illustra- tion, demonstrate this progressively improving covering power enamels. Besides saving per cent cover coat requirements, compared with last year’s needs, the advantages claimed are greatly increased resist- ance mechanical shock and deflec- tions, greater resistance scratching, practical ,elimination chipping, and the production enameled sheets that shear neatly with chipping back from the edges. Ultrapaque enamel frit supplied the enameler powdered form, pre-ground that per cent (CONCLUDED PAGE 80) | Wa 4 ti the Sin n, TTEMPTS eliminate the aero- projecting, brazier rivets aircraft fuselages led the develop- ment the flush head rivet and the same time created production prob- lem relating tooling and costs. has been successfully solved after con- siderable research the plant the Curtiss Aeroplane Division. driving airplanes tremendously important factor. estimated that the cost driving each rivet under the old method averaged 5c. per rivet, which amounted $2,250 per ship typical example containing 45,000 rivets, which 30,000 are external. described was estimated that flush riveting might raise the cost much per rivet, $6,750 per structure. Detailed time studies and estimates based however, that the increase would much less. (See Table I.) Through the development new techniques and new tooling, however, the added cost for flush riveting actually only about per cent. First point attack the problem was the method countersinking the holes the skin. Press countersink- ing obviously faster than machine countersinking and particularly ap- plicable aircraft fuselage work since only small portion skin sheets ever exceed 0.051 in. Press countersinking first applied, however, was one the contributing causes the development cracks around the edges the holes the second sheet. This cracking has been obviated several changes tice: The first point attack was the de- sign the rivet itself. was the depth head the standard AN425 rivet that necessitated large amount deformation the sheets and led cracking the hole edges when press countersinking was resorted to. Consideration was given changing the angle the head, but this modifi- cation was abandoned because the Abstracted from paper presented the author the National Aeronautic Meeting the Society Automotive En- held Washington, March 16. included angle the head increases, the ratio change outside diame- ter head with changes depth tol- erances becomes greatly amplified. Hence the 78-deg. included angle retained, but the rivet head height has been reduced from 0.063 0.046 in., thereby reducing the head diameter from 0.226 0.200 in. See Fig. was also found that cracks the edges could avoided elimination the redrilling operation the sec- ond sheet. the case rivet, this means drilling directly size with No. drill (0.1285 in.), whereas the earlier practice had been first use 0.094-in. drill, followed redrilling with No. drill. Other contributing factors successful press countersinking were: (a) The development suitable press countersinking die angles, Fig. also tapered toward the hole and con- sequently prevents serious enlargement the hole which would conducive (b) The chamfering the inner edge extrusion shapes and formed stringers prior press countersink- ing; also chamfering the inner edge the inner sheet. (c) The use linseed oil lu- bricant punches and dies. This oil was chosen because does not interfere with sub- sequent painting operations. the flush rivet develop- ment program generally prescribed press countersinking the sheets and inner members means slow hit- ting hammers. This procedure has been largely replaced pneumatic squeezing, since this technique elim- inated the general necessity two- man teams countersink, thus reduc- ing the cost and improving the accu- racy the operation. connection with this squeezing operation, was found that spring loaded stake, Fig. was very helpful that prevented rivets from flashing sheets. Proper selection punch and die angles and diameters also impor- tance order produce forged condition with the where the head seats the outside the skin. Otherwise thin gage sheets radius would result this point, causing unsightly gap around the rivet head and also bulging between sheets, condition illustrated Fig. Punches and dies must have pol- THE IRON AGE, April 13, ay § F Chief Curtiss Curtiss-Wright Carp. j the standard AN425 rivet reduced head height and head diameter one the factors the successful application this type flush rivet airplane fuselage construction. Satisfactory that are press countersunk such manner leave radius around the edge the hole gives unsightly appearance LEFT 2—For press counter- sinking the rivet holes, die angles have been selected that the skin formed also tapered toward the hole, thereby preventing serious en- largement the hole which would conducive cracks emanating from the edge. RIGHT stake, when used air- operated toggle squeezer, holds the sheets tightly to- gether during press counter- sinking and riveting operations and prevents the rivet stock from flashing between sheets, besides assuring tight set and are likely lead bulging the skin sheets between rivet holes. This condition corrected the selection the proper die angles actually forge the material sharp corner during press counter- sinking. TABLE TIME STUDIES BRAZIER AND FLUSH RIVETING ished surfaces and accurate within close limits. Dies for press counter- sinking are formed cold pressing under high pressure. Fig. shows the OPERATIONS master die parts and the countersink- Brazier Riveting Operations—Actual ing dies. After machining, the Minutes crowned face given high polish. Stack drill 0.094 in. per hole per The blank then assembled within 0.05 Assemble skin stringer with screws, one five holes........ 0.19 Drill 0.094 in. through undrilled TABLE 0.15 Best Riveting Practice With Latest Tooling inutes Stack drill (0.094 in.) 1.005 per hole per sheet... 0.055 0.055 Flush Riveting Operations—Estimated 0.05 0.05 (Machine Counter Sinking) Minutes spring Stack drill 0.094 in. per hole per 0.15 0.15 0.05 Remove skin and press Assemble skin stringer with countersink ......... spring fastener holes..... 0.19 Machine Drill 0.094 in. through undrilled 0.49 Rivet (multiple rivet- Machine countersink 0.15 0.12 0.16 1.205 0.845 0.575 32—THE IRON AGE, April 13, 1939 the master die and subjected force The outside diameter then turned size and the hole reamed, followed heat treatment. Punches for coun- tersinking are also cold pressed similar manner. The operation sheet, shows how considerable reduction mini- mum time has been effected flush riveting over the former brazier rivet- ing operation. Operations and remain unchanged. Operation was more readily assembled and disassem- bled than screws. not possible, however, use the spring fasteners all assemblies, and wedge and pin screws are still used, particularly certain portions the fuselage. Operation has been eliminated and the new operation combines ing and machine countersink- ing means special countersink- ing tool, Fig. Operation auto- matically improved that brazier rivet requires that cupped set accu- rately engage the head, necessitating greater care than with flush rivet for which only flat set need used. | 4 f “AA SA = = A Af, AA LAA A, q q ( e n 0 5—Operation cold punches and dies used flush riveting operations. 7—Typical rivet driving tools used pneumatic squeezers for setting flush head rivets. Machine countersinking the skin involves problem accurate depth control, using tool and non-rotat- ing stop. shown Fig. the stop held contact with the skin spring prevent chips from get- ting under and scratching the sur- face. Generally multiple flute coun- tersinks are used, although single flute countersink shown, which practically free from chattering. There have also been other means employed for cost reduction. Gang multiple riveters which drive eight ten rivets simultaneously permit one operator drive 6000 rivets 8-hr. day. With helper place rivets the holes the output per day doubled. Hopper feeds are also being developed for this purpose. New types fast operating, deep- throat squeezers for press counter- sinking and riveting have also ma- drill and countersinking tool used preparing holes for flush rivet- ing airplane skin structure. The spring-loaded collar helps holding the sheets together during this operation. 8—A special feature the rivet driving tools that holding the sheets tightly together means suitable spring loading during the operation. ° ° latest units for setting countersunk head rivets aircraft fuselage, such described Mr. Berlin, this Tomkins- Johnson hydraulic unit with automatic maga- zine feed. 12,000 lb. pressure can ap- plied rivet. terially aided reducing cost, par- ticularly through the use special high speed hopper feed riveters. Another important change has been the rivet material itself. First, through the use 17S rivet material place 17ST aluminum alloy, ap- proximately 0.2 min. per rivet has been saved due the elimination erator service, handling, etc. Later the 17ST material was changed eliminate the cost the critical handling that the former required and avoid the removal over-agehard- ened rivets that become defective upon driving. THE IRON AGE, April 13, —— le Table, ik- for rtually converting machine into reduced ssible ° ° ide flexibility ions impo More rigidity and the modern turret older type the same machine these machine shop. the time min. bevel gears Hy-Ten B-4 were machined min. each, obtain the past flexibility control mod- ° turning turret lathe lathes prov operat \ _ q ith engine ing 2400 and upper for mak lower plu ing turret lathe ime has been cut — was formerly cross feed brake the EE RODUCTION these valve bod plugs, lathe. heads turret ible rtually into D. RIGHT makes its own tur- ret stop screws, and new machines have hastened their output shaving per cent from the previous machining time. BELOW operations are used making the stop screws, requiring two chuckings and from threading drilling number hole. The time saving was largely due automatic speed selection. ODUCTIVITY per man and machine hour the one big for the factory manager approaching cost re- duction nowadays. And modern machine tools amazing job this respect. Here, for example, are some case studies based the operation the latest Gisholt turret lathes. This first series covering broad range machines and products. 4% e we FORKNER Chief Engineer, Federal Machine Welder Co., Warren, Ohio contribution toward greater efficiency the handling and use wide strip stock has been made through the development special combination machine for welding wide strip sections together, end end, prior the pickling oper- ation. This has been common practice for some time strip stock reasonable width, but very wide stock the time element welding and stripping, distortion the sheet, and inconsistent welds all have contributed make the practice uncertain. The speeding the continuous pickling process likewise has helped make welding machine more difficult some cases the 36—THE IRON AGE, April 13, 1939 speed may reach 100 125 ft. per The sequence operation the Federal machine follows: the coiled stock comes from the hot mill deposited leveling processor, the end the outmost con- volution being entered between the rolls and proper pressure applied, de- pending the gage stock being handled. addition leveling, the proces- sor removes much the scale, thus improving contact the welding dies. Immediately beyond the processor air actuated jack the center, the purpose this jack being raise the sheet stock form pro- necessity concise alinement the processor relation the welding machine when the centering mechan- ism the welder performs its func- tion, and also provides necessary for closing the welder after trimming just prior welding. How- ever, the jack not engaged until shear (stationed between the table and the welder) has performed its function cropping the fish tails from the end the sheet and the sheet fed into the welder its proper location preparatory weld- ing. Cropping the sheet end not considered final preparation for welding. Facilities for the final trim are contained the welding machine proper. After cropping, the sheet en- ters the pinch rolls the welder, which feed the sheet into the welder. This operation controlled from the operator’s station. The operator then causes the sheet progress until the leading end approximately in. in. beyond the weld line face the upset platen die. this time the air actuated centering mechanism performs the function alining the sheet relative the center line the machine. This mechanism continues exert pressure the side edges the sheet until pressure relieved from the pinch — | o \arge \45 ' . beind wi e 78-1"- \ess 1 ( t 0 t a W be rolls. When the upper pinch roll re- tracts the sheet free adjust itself the centering mechanism, prior being clamped between the welding dies. Much time and thought were given providing efficient clamping ar- rangement order overcome exist- ing difficulties experienced welding wide sheet stock. result, slide ways for bringing down the clamp arms were eliminated having the arm position, thus reduc- ing wear. Offsetting, countering the deflection the arm, under re- actions approximately 125,000 Ib. each end, was necessary. This was accomplished supplying the arms with multiple sections, individu- ally spring loaded. Not only does this arm insure positive clamp- ing pressure the entire width the and also the driving screw, and the sufficient length permit enough over-travel the arm the front back side the welder the clear when driving power unit. the machine closed for welding. The entire sequence operations has, far, been follows: The leading end the incoming sheet has advanced through the processor, across the table containing the air jack and through the upcut shear. then enters the pinch rolls the welding machine and passes through The sheet halts desired location relative the weld line face the upset platen the centering mechanism. die. remaining this position the air jack the table caused function and the processing leveler halted. Pressure the welder pinch rolls relieved and the sheet dies are raised avoid drawing the sheet across the face the lower dies. These rolls remain position until repeat welding sequence again reached. The name applied the shear stripper, which patent, renders further explanation unnecessary, with the possible excep- tion mentioning shearing knives both above make this type stripping pos- sible was necessary provide clamp gripper with sufficient capacity apply pressure for holding the sheet while pulling through. This pres- sure provided through multiple cylinders. Also, the travel this gripper, which sufficient range for absorbing the angle the shear stripping knives, hydraulically sheet, but also insures the electrical contact for the entire width. The sheet now clamped posi tion undergo final trim just before welding. Likewise, the trailing end the sheet, which has already been through the sequence set forth for the entering sheet, trimmed the same time, while clamped the op- posite die the stationary side the machine. The trimming device quite unique velding machine. Its function utmost importance alining the two edges stock with unerring accuracy. definitely controls its speed pas- ses through the 24-in. tween welder dies. Also the height the rotary trimming (similar fixed vertical position. The arm which contains the trimming as- sembly proper very rigid design and suspended from horizontal mem- ber. This member mounted rigidly the very top the the guide ways for the arm properly positioned the centering mechanism, after which clamped between welding dies and the final trim made. Immediately following quence, the movable platen the ma- chine advances the position be- ing ready weld. previously explained this travel means verse drive. With precise timing the cam roll lever alinement between the upsetting cam and the upset platen. The upsetting cam drive engaged this instant and the weld performed, thus bond ing the leading end the incoming sheet and the trailing end the sheet preceding it. Without further hesita tion the upper dies the upset platen and the stationary side are raised order free the sheet for pulling through the snow plow ping arrangement, which this time closed sheet thickness. Simultaneously with the raising the dies group sheet lifting rolls are immediately back the Upon completion the gripper travel two hydraulically actuated side clipping dies are brought into action. Their function trim the sheet each side edge directly line weld. This quite important, removes that portion surplus weld material that the plow shear stripper does not reach. The hazard in- juring the rolls the mill following the pickling operation eliminated. The operator now pinch rolls the outgoing end the machine and the stock taken through with sufficient rapidity posit enough stock looping pit supply the pickler while another weld being made. The magnitude this machine may visualized its ability weld sheet in. wide 3/16 in. thick, cross section over 14.5 sq. in., time often less than min. The producer gains continuous process the mill and avoids loss time. And user this wide material enabled, likewise, set continu- ous process through punching and forming machines. THE IRON AGE, April 13, 3 4 en nis ire ich £ example another type im- peller cast monel metal shown Fig. this case the center boss about in. diameter spreading out in. diameter where joins the shroud. There further thickness metal attached this shroud for the packing ring shown and the sectional view. The blades his impeller are only 5/16 in. thick, while the shroud Paper presented before the Scottish the Institute British Foun- drymen. Main core 38—THE IRON AGE, April 13, 1939 CAMPBELL in. and the packing ring in. thick. There extremely heavy section metal the boss. cast the normal way, shown the previous example the extrac- tion pump impeller, Fig. shrinkage would occur this heavy section. order overcome this the method molding was reversed obtain risers over the center boss and from the packing ring, shown. Further, avoid cracking and give more even heat distribution, two side gates cut the parting were used. This arrangement gives direct access all the blades and has been found the most successful method casting this type impeller. Two hand are required cast these impellers points and The sprays used are LEFT 8—To avoid cracking and provide more even heat distribution casting this monel metal feed pump impeller, two side gates, cut the parting line, were used. BELOW 9—Direct dirt trap gates were employed casting this gun metal valve body. Average section thickness 7/16 in. Pouring Downgate rectangular section in. in., while the downgate in. diameter. The following examples were cast Admiralty gun metal having approximate analysis per cent Cu; 9.5 per cent Sn; 1.8 per cent and 0.5 per cent max, Pd. dealing with the gating and feeding this alloy, the main points are:— (1) The sprays should larger area than generally required for cast iron; and (2) while risers are neces- sary deal with liquid shrinkage some cases, feeding more less regulated the casting temperature. There has been ample evidence shrinkage cavities due too low casting temperature. There wide divergence opinion the correct casting temperature, due possibly the fact that various authors have mind different kinds castings and different foundry conditions. examples given above, the casting tem- perature range the metal was 2156 2228 deg. gates from center this, the second and final chapter Mr. paper, the gat- ing and feeding monel metal, gun metal and high tensile bronze are discussed. the first chapter, pub- lished the issue March 23, 1939, the fundamentals gating and feed- ing and their application cast iron were covered. The Age in- debted the Institute British for permission publish this material. Fig. shows the section and plan valve body, fairly uniform sec- tion. The manner which this body gated will serve illustrate clean and successful method and can, ‘with modifications, applied numerous types castings. shown Fig. Communicating gates center Sprays the metal enters the mold through flanges and two in-gates, and the direct dirt-trap type, correctly proportioned. Risers taken from the casting the points shown overcome liquid shrinkage, feeding be- ing governed correct casting tem- perature. The plan and section mold for large gunmetal de-aerator casting, weighing approximately two tons, and 7/16 in. average thickness, shown Fig. 10. account its size and section, the gating had consider- very carefully, more particularly since internally the casting had baf- fle box attached ribs the external contours the casting. Arrangements had made get the hot metal this box well provisions for casting the outside contours. The fol- lowing arrangement was found give satisfaction avoiding mis-run. Provision was made for casting with two ladles, one either end the enlarged view shows the arrange- ment sprays for the casting illus- trated detail Fig. 10. 10—Because the size and section this casting, the gating and feeding methods used were particularly important secur- ing sound casting. 12—Sprays for high tensile bronze should flared the joint avoid creating fountain effect the metal entering the mold. THE IRON AGE, April 13, 3 3 Y ar riser Assembled Mold Finished Casting 13—The greater shrink rate high tensile bronze imposed added problem selecting the proper method gating and feeding this turbine pump casting. mold. Fig. 10, the main core print, two channels were cut and each was fed main gate. Eight sprays were taken off these channels and en- tered the mold flange trated the diagram the sprays, Fig. 11. These main gates were in. diameter, while the sprays were in. other end the mold, and entering stools the bottom the mold, two additional main gates each having spray which entered the stool the flange. These gates were in. diameter, while the sprays taken off were in. sq. Note arrangement by-passing the metal dummy riser order ensure cleanliness. This arrangement did not succeed getting the metal the bottom the mold, and would have risen the mold about ft., and then tumbled back into the cooler branch, which the bottom the mold, and might have caused cold shut. avoid this the stool flange nearest this branch was connected two sprays, shown and Fig. 10. These sprays were in. this arrangement, im- mediately the stool flange became full metal, was by-passed the bottom the mold. Finally, top side the mold four drop gates were used were arranged pass down the metal thickness the top stools, which, 40—THE IRON AGE, April 13, 1939 turn; were connected ribs the baffle box internally. casting, these gates were plugged, and gates and started first. When was judged that the metal had risen the interior the mold the bottom side the baffle box, these plugs were removed and hot metal al- lowed drop the rising metal. These gates were in. in. Risers were taken off shown R?, and whistlers, shown arrows Fig. 10, the box core assist elim- inating any chance air lock that portion the casting. The alloys from which examples are given herewith are made approxi- mately follow: Cu, per cent; Zn, per cent; Fe, 1.7 per cent; Al, per cent; and Mn, 2.8 per cent. The ten- sile strengths the as-cast condition are the region 76,000 84,000 Ib. per sq. in., with elongation per cent. This alloy has extreme- high liquid shrinkage, and this account heavy risers feeding heads are required. Gating has such that little turbulence possible oc- curs when casting. This turbulence causes the formation zinc oxide which, like sand, highly refractory, and forms inclusion the detriment the casting. Sprays, therefore, must situated the lowest point the casting and shaped shown Fig. obviate “fountain” effect. Cast- ing temperature also important for the same reason with gunmetal. The most satisfactory casting tempera- ture range for this metal, the author’s experience, 1814 1868 deg. shows section through the assembled mold and cores turbine pump casing bronze. 14—This tration shows the location risers and gates three throw pump and valve box casting. Figures and illustrate the prob- lems involved pro- ducing this work greater detail. This pump has oil box with bear- ing attached the main pump body. The average section about in., while the pump itself varies from high shrinkage the metal the pat- tern was made that the heavy pump sections were the uppermost por- tion the mold. The oil box was arranged the bottom. gate was formed shown and stepped down gradually from the second the first parting, finally enter the mold spray the flange the bottom the oil box This gate was in. diameter. After step- ping down the first parting was reduced in. diameter, while the spray was in. in., opening out was stepped down through the second parting the first and finally two sprays were taken tangent the lower portion the pump body, shown and This gate was in. diameter second parting, then stepped down in. diameter, with two sprays in. in., increasing 234 in. in. The total depth casting was about addition, riser was taken from the discharge branch shown This branch was, turn, connected the suction branch immediately below, in- dicated This overcomes the high IG. elim- inating block cores and casting solid, illustrated right, the shrink- age holes shown Fig. were elim- inated and sound casting ° ° inally cast with cores, shrinkage de- fects the casting shown full Fig. developed the points marked a shrinkage which occurs after casting. When casting, both main gates were plugged until the runner’ head was filled. While still pouring, the plug the downgate was withdrawn and the metal allowed rise the mold the first parting. When this was judged the position the metal, the second plug for gate was with- drawn and metal allowed enter sprays and and casting was con- tinued until the head was filled. About tons metal was required cast this pump—3500 Ib. for the pump and 1500 for head and risers. The gates were stepped described or- der have little turbulence pos- sible. addition the feeding heads described, denseners (or chills) were necessary overcome shrinkage Figs. show the top box plan, These cores used ultimately dispensed with and job cast solid mid-section, plan-section, and cross- section three-throw pump and valve box which was cast high- tensile bronze. Originally, this casting was made with cores, shown Fig. 15, directly through the cylinder and valve with chills marked the heavy flange side the cylinder, overcome the shrinkage which oc- curred the junction the metal between this flange and the cylinders the points indicated One gate was stepped down the bottom this heavy flange, shown Fig. This gate was in. diameter, and stepped down part- ing in. diameter with spray flange in. sq. opening in. sq. second gate was stepped down the top end but the opposite side this heavy flange, and was also in. diameter with 2-in. sq. sprays opening in. third gate was taken the parting, thence direct the valve box flange. This was also in. diameter, with 2-in. sq. were taken off flanges while the valve box and main heads were taken from top cylinder, shown Fig. 14. Originally the section varied from cylinders and the heavy flange the bottom casting. When the casting was made means center cores, Fig. 15, and chilled previously de- scribed, trouble was experienced with shrinkage the points marked all down the junction the cylinder and the heavy flange. overcome this, these center cores were finally removed and the casting made solid, with the exception the pipe connection core shown marked Fig. 15. doing this the shrinkage trouble was over- come and successful castings were ob- tained which withstood 2500 Ib. per sq. water pressure. This casting required three tons metal cast, care being taken that the temperature was the region 1832 deg. THE IRON AGE, April 13, CARD ° ° POTTY demand one the tribulations the power boiler industry that not likely eradicated. were seasonal de- mand, and designs could stand- ardized dimension, some the slack season time could devoted advantageously manufacturing for stock, preparation serve quick delivery orders when business picked up. But this can’t done with cus- tom built product. some respects the trend toward higher steam pres- sures has not improved the situation, because the trend has involved change construction method from riveted welded boiler drums, and the latter can manufactured only tested and certified organization. Enforcement governing the construction boilers starts right the manufacturer’s The purchaser cannot ex- posed any risk failure, because boilers simply are not shipped until they have been thoroughly checked for every possible defect workman- ship. The situation further compli- cated because the cedure gets under way advance all manufacturing operations, with 42—THE IRON AGE, April 13, 1939 check the skill and proficiency each welding operator. Qualification Tests Added Expense Under such conditions, peaks and valleys production can readily work greater hardship than many other fields, because the laying off quali- fied welders slack periods means that new ones have found when business picks up. And this not merely matter finding many skilled men. There the added expense putting every new em- ployee for that department through qualification tests for every one the procedures which will use; and common knowledge that qualify- ing expense normally several hundred dollars per man. present, fabricator cannot meet emergency hiring welders who have qualified other shops, because the testing program mandatory without regard experience rec- ord previous qualification. There- fore highly desirable keep organization intact. well worth noting further that employers welders for this class work are general agreement that the only way get good operators train them, bringing them from one grade another over period months. compensating factor has appeared construction has added the desirability leveling production peaks and valleys the power boiler industry. Welded drums can manufactured only certified welders, the laying-off whom means added expense requalifying them qualifying new welders when larger force needed. Furthermore, the valleys may involve the loss operators who have been progres- sively trained the company for Class work. the growing demand for unfired pressure vessels well great variety welded special equipment for the processing industries, articles which may may not come under = | | f | ty 5 the jurisdiction any the codes, and yet, the nature their ser- vice, can satisfactorily produced only plants which have the special facilities and the trained personnel the Edge Moor Iron Works, peaks and valleys are smoothed out the use its boiler building facil- ities for variety other pressure vessel work requiring somewhat the same class workmanship. System- atic scheduling production avoid congestion and delay any one de- partment and assure maximum use all fabricating equipment also feature. The second part Mr. Card's article will appear early issue. which takes welded work that meets code requirements. This has been the experience Edge Moor Iron Works, Edge Moor, Del., where tube boilers are water product the same shop which fab- ricates wide variety pressure vessels and process industry equip- ment. Incorporated 1868 the Edge Moor Iron Co., this concern for many years did large business the nor- mal run structural iron and steel work. About 1895 began the manu- facture line box header boilers, and these turn gained reputation which justified the large investment machinery improve- ments and the organization cap- able workers from the engineering staff down through The box header boiler, however, lost its place the market when the trend higher steam pressures opened the way for the bent tube boiler. was not only new design that was demand, but new method construc- tion, because electric welding was supplanting the riveting operation for making boiler drums. the engineering staff designed new line bent tube boilers, and the shop staff installed welding machines, to- gether with X-ray apparatus and stress relieving equipment which were necessary under the new regulations boiler construction. welding department was developed, qualified and put work, and Edge Moor went market with modern boiler meet the modern demand. Company Reorganized brief word two history may useful here bringing the organi- zation picture date. William Sellers, second president pal owner the original company, died June 1933. The trustees the Sellers Estate desired convert the property into something more suitable for trust fund and soon arranged so. Edge Moor Iron Works, Inc., was August, 1936, and purchased the complete business and plant the old company. Thomas Dillon, presi- dent and principal owner the new company, has shown his high esteem former employees retaining many them possible (about per cent) the present payroll. For example, Shively, secretary and general manager, started with the company about years ago, Flower, chief engineer the boiler division, years ago, and THE IRON AGE, April 13, a i | Hughes, went work there 1903. During the days when riveted boil- ers were being made Edge Moor the demand for other types plate fabrication was growing, largely steel and chrome iron and steel tanks and pressure vessels. The range this work has increased amazingly years under the influence ad- vanced designs processing equip- ment and the development numerous special steels rous alloys, now widely available plate and other commercial shapes, each with its own range corrosion resistant properties. The fabricating division this plant has enjoyed corresponding increase scope, and derives business from dustries—petroleum, pulp and paper mills, chemical plants, food plants, dye works. Sizes will vary from bubble tower that requires two cars for its loading, down jacketed vessel small that this huge plant looks like toy tea kettle. Class Welding Required for Most Work Although per cent the welded work done the plant executed accordance with code requirements for Class Class pressure ves- sels, generous portion the fabri- cating division’s business the form articles which governed codes. Instead, the cus- 44—THE IRON AGE, April 13, 1939 tomer specifications call for standards process qualification, operator qualification, that are almost identical with code re- quirements. other words, buyers have considered necessary write specification which can only met Class welding organiza- tion. active divisions occupying the same quarters and using the same production equipment might pected get each other’s way, par- ticularly when the one makes will explained later, because preferable first have general idea what goes this 24-acre plant. Flow Work Illustrated Over period several years has become evident that machines and tools that were installed primarily for boiler construction are time savers well other varieties work, nearly everything gets used some extent the miscellany special jobs. Therefore survey the flow work incident the con- standard product routine manner and the other produces never end- ing variety sizes and shapes; but there not the slightest evidence conflict here. One good reason that although the boiler division and the fabricating division are separate and specialized the sales and engineer- ing departments, when they reach the shop they merge. Since the shop or- ganization not definitely split into two parts, works unit every job that comes in. Standard jobs and specials, large jobs and small, long jobs and short ones, flow smoothly