The Iron Age 1939-05-25: Vol 143 Iss 21

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati Boston Hambura, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Newark, N. J St. Lowis JR. Owned and Published by CHILTON COMPANY (Incorporated) Editorial and Publication Office Executive Chestnut and 56th Sts., 239 West 39th St., Philadelphia, Pa. New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC STEVENS. Vice-President JOSEPH HILDRETH, Vice-President GEORGE Vice-President EVERIT Vice-President WILLIAM BARBER, ‘Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE THOMAS KANE, CHARLES BAUR, BAUR, General Advertising Manager 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- ada, $8.50; Foreign, $12.00 year. Single cents. Cable Address, “Tronage, N. ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland Herman, Chilton Phila. H. K. Hottenstein, 1012 Otis Bldg.. Chicago Leonard, 239 39th St., New York Peirce 7810 Woodward Ave., Detroit son W. J. Fitzgerald ¢ 428 Park Bldg., Pitts. Warren, Box 81. Hartford, Conn RON Contents MAY 25, 1939 Who Won the Coal Strike? Foundrymen Sift Casting Problems Tin Plate Irvin Works Steel—Problems Manufacture and Use Gear Makers Discuss Developments Long Boom Cranes Bridge Assembly Year's Progress Foundry Equipment Thermoloy Process England Makes Steel the Assembly Line Washington News THE NEWS BRIEF Statistics Metal Working Activity Weekly Ingot Operating Rate Rate Activity Capital Goods Plant Expansion and Equipment Buying New Industrial Literature Products Advertised Just Between Two Index Advertisers Copyright 1939 Chilton Company 102 106 118 119 142 ae ent ith hat ick hly ate the for hat een ave Ryerson Stee Reduce failures eliminate spoilage and get better results lower cost using Ryerson Cer- tified Steels—steels that represent the highest quality obtainable each different classification. Ryerson Certified Steels you are assured the utmost uniformity—freedom from hard spots— desirable bending and fabricating characteristics that reduce shop labor costs and help produce sound dependable jobs less time. alloy steels where results are dependent heat treatment, Ryerson selects whole heats each analysis—tests and actually heat treats bars determine their response then compiles com- plete data guide the heat treater securing the best possible results. does not have test guess take chances. knows the istics each bar steel with which working. Ryerson Certified Steels also include carbon, tool and stainless steels that meet definite high standards uniformity and quality. They offer safe, sure way getting maximum value from your steel dollar. Let send you the Ryerson Stock List show- ing the full range Certified all shapes and sizes—carried stock for immediate shipment. Joseph Ryerson Son, Inc. Plants at: Milwaukee, St. Louis, Cincinnati, Detroit, Cleve land, Buffalo, Boston, Philadelphia, Jersey ie | { 7 ... THE IRON AGE ... MAY 25, 1939 ESTABLISHED 1855 Vol. 143, No. Who Won the Coal Strike? labor controversy, such the recent coal strike, dies through settlement please, determine who won, anybody, and who lost. would say that John Lewis could numbered among the winners, thanks Presidential intervention. For John has been standing pretty slippery footing the courtyard public opinion, and his feet might well have gone from under him had not been for the timely application the helping hand from Wash- ington. is, John wins the union shop, least for some per cent the industry, which virtually means that has won the closed shop, since any non-union miners the plants must join the UMW within stated time hold their jobs. John has won respite from the toboggan slide that his rapidly disintegrat- ing labor empire was approaching, together with the prospect the continuance the dues money which came handy for past campaign contributions. Next John among the winners, would pick out the oil industry. has gained, direct effect this latest attempt seize consuming public the throat, what will equivalent annual oil sales several million tons coal, judg- ing merely announcements conversions oil burning already made. While shar- ing the winning honors with Mr. Lewis, the petroleum industry does interested bystander and not contestant. owes the gains that have been thrust upon not all Washington and altogether Mr. Lewis. would nice gesture send him vote thanks. the politically minded, with eye 1940, Washington may classed among the winners. Certainly would seem that two rescues performed two different hours need should have squared any campaign contribution and left something the debit side for Who lost the strike? would say that the United Mine Workers were thé prin- cipal losers. Not only did they lose some six pay, but what more serious they face recurring annual loss perhaps much through diversion consumption from coal oil. ng. would indeed seem short-sighted labor leadership industry drive con- sumers away from through duress and thus penalize its workers. Americans won't tolerate dictators. The coal industry has long been called industry. Maybe would bene- nt. v0, * q ae | £6 Bie SHEETS STRIP after reasonable quantity steel sheets have been put through forming and finishing operations after all time losses and rejects are accounted for then, and then only, can you tell how much your steel costing you. Can this cost reduced? You may think saving can made. But why not make sure? Put this question Inland metallurgist, for his business know the answer find for you quickly. surprising number cases Inland Men are able find new economies ways im- prove the result. You will like the friendly way which your nearest Inland Office will co-operate whether you need steel information about it. TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS RAILS TRACK ACCESSORIES REINFORCING BARS South Dearborn Street, CHICAGO District Offices: DETROIT question why different are used the pro- duction identical parts asked great many times. For this reason, would seem appropriate discuss the results obtained stituting castings for certain forgings the automotive and allied fields, and what the future has store for the casting industry such the choice material for any part, there are number factors given consideration, for instance, (1) what are the requirements service? (2) can the material pro- duced uniformly? (3) what the overall cost the finished product? Whether the choice casting forging many cases matter personal opinion. course, many engineers are steel minded, and the choice casting would furtherest from their consideration. But, true that stresses, method fabrica- tion, possible change design, and necessary often favor cast- for many parts. However, plant equipped for ma- chining certain forging type which can cast and ground more cheaply might find difficult change casting due the cost in- volved scrapping good equipment. occasion, different accounting General Motors Corp., Saginaw, Mich. CARL JOSEPH* HIS metal, arrested mal- leablized steel, combines the simplicity and adaptability castings with strength re- liability similar forgings. rapidly gaining favor for cer- tain automotive applications, applications involving high stress and fatigue. The metal- lurgy, production practice, heat treating technique, physical properties and applications are all discussed herein. methods various plants using identi- cal parts will account for the fact that forging used one instance and casting another. This espe- cially true when the part question forged the plant’s shop. this instance, the part can produced more cheaply casting outside overhead the balance the forgings would actually raise the cost the remaining forgings. There- fore, there would some hesitancy changing over casting. However, very often due the obsolescence existing equipment, any saving which can made the purchase new equipment will interest engineers the use castings over forgings. Notable savings production costs. and many cases marked improve- ment the quality the product are the results obtained with known the trade ArMaSteel (arrested malleablized steel). The metal duplexed cupola electric furnace material which produced under the most exacting technical con- trol. Very close chemical control maintained from the raw materials the finished product. The metal charge consists per cent high quality steel scrap, per cent silvery pig iron, and the balance gates and sprues. The melted metal tapped from electric furnace 2850 deg. F., after being refined and superheated. The TABLE Properties ArMaSteel, Oil Quenched and Drawn Ultimate Strength Lb. Per Sq. In. 108,000 105,000 95,000 Yield Point Lb. Per Sq. In. 95,000 90,000 82,000 Per Cent Elongation In. Hardness THE IRON AGE, May 25, é q £ Wey ; ° No. 3.6 285 2.5 3.7 269 analysis the metal follows: Carbon, 2.65 2.75 per cent; silicon, 1.25 1.35; manganese, 0.38 0.42; sulphur, 0.15; and phosphorus, 0.05 per cent. The properties ArMaSteel com- pare favorably with steel castings and forgings the 1035 range. The metal combines the simplicity and adapta- bility casting with strength and reliability similar forging. And certain instances articles cast more economically from ArMa- Steel than forged steel. The product originally cast white, all the carbon the combined state. then heat treated such manner that the graphitization allow com- bined carbon main definitely affect the The ma- trix ArMaSteel can controlled contain com- bined carbon from very low percentages the eutectoid composition about 0.65 per cent. The properties ArMa- Steel differ the matrices differ— the higher percentage combined carbon producing the stronger, harder, less ductile and more difficult product machine. Due the incomplete graphitization ArMaSteel, the shrinkage from pattern size slightly greater than that malleable iron. This shrinkage depends upon how much combined carbon present the iron, but generally the same pattern shrinkage for malleable iron cast- ings, 1/16 in. per ft. The combined carbon ArMaSteel present sorbitic structure and also the form minute spheroids iron carbide imbedded the matrix the iron. When heat treated, mar- tensite, some other form decom- position product austenite, will produced. Just steel treater heat treats tool steel, i.e., quenches rapidly oil water obtain hardness and “draws back” temper remove strains, ArMaSteel also treated. With ArMaSteel, the time- temperature factor important, due the reabsorption carbon the temperature and time are increased. The development work such ArMaSteel dates back some years. Early experimentation was given practically encouragement engineers, and has been only during the past few years that any real prog- ress has been made production 28—THE IRON AGE, May 25, 1939 ArMaSteel cam shown above. The 100 diameters, and show face the top, the gradation zone the middle and the core the bottom. This cam tested 65,000 per sq. in. yield, 85,000 ultimate, per cent elongation, and 196 217 Brinell, with Rockwell the surface. The total carbon was 2.70, combined carbon 0.49, man- ganese 0.40, silicon 1.25, sulphur 0.16, and phosphorous 0.05. the product. Most automotive engi- neers and metallurgists are inclined put aside the marked improvements metallurgy applied foundry operations, which have been developed the past decade. Foundry practice for years has largely been art rather than science, but science far more prominent. There has been tendency recent years replace certain forgings castings the automotive field and other industries. This competition both the car producer great advantage favor castings the possibility placing metal exactly where will the most good. This eliminates ing. Constant pressure brought foundrymen re- crease physical properties and cut manufacturing costs has stirred the inventive faculties the metallurgist the pitch, many cases has caused him venture into hitherto un- exploited fields find new uses for castings, uses which have often been considered out- side the range practical accomplishment. ArMaSteel has large potential out- properties made possible heat treat- ment. When soft quite easily machined. Comparative machining tests show that ArMaSteel has ad- vantage over steel bar stock and drop forgings the same Brinell hardness. Reports from Saginaw Malleable Iron Division customers show from per cent better machineability, with 100 per cent increase the number castings per tool grind. ArMaSteel parts take fine machine finish with high polish. Experience machining ArMa- Steel rocker arms has shown that the material machines better part now being machined 303 r.p.m. drill speed with production 1000 more castings per tool grind. 25/32-in. drill used for this operation, and 303 r.p.m. this gives stock removal 0.011 in. per revolu- tion. The rocker arms formerly were made from steel forgings, which were machined 520 r.p.m., with stock removal 0.0064 in. per revolution. this drill speed, 500 600 castings per tool grind were obtained. other words, ArMaSteel must machined lower with greater feed increase the number parts per tool — | | > | . | grind over similar part made steel. turning 2-in. bearing cer- tain camshaft forging, the part was machined 134 r.p.m., with 0.011- in. feed. ArMaSteel this has been cut per revolution. camshaft was formerly 1045 forging. The present ArMaSteel camshaft offers machining trouble, and ma- chines considerably better forging. Another comparative machining test 1145 steel forging and Ar- MaSteel was made sal joint yoke. The splinning op- eration the forging 3.8 gives considerable trouble duces chatter the tool. The broach the forging was 11,000 Ib. against 5500 Ib. the other lot forg- ings tested against ArMa- Steel 3.6 mm. Brinell, load the broach was between 11,000 and 12,000 The ArMaSteel shifter fork one make car flame hardened applying the heat the surface hardened for period sec., fol lowed water quench. This pro- duces file hard surface. another car the ArMaSteel rocker arm pad allowed remain min. lead bath held 1550 1575 deg. and quenched oil. The pad end immersed the lead depth in. and the remaining portion the arm not heated, there- fore, not affected. has been possible eliminate the use bushing many tests have demonstrated the company that the wearing Rockwell are superior steel were conducted camshafts and rocker arms. Specifications Tocco hardened ArMaSteel cams call for Rockwell Hardened pad ends rocker arms are held minimum Rockwell The correct quenching temperature and medium used particular part treated must given care- ful consideration. The lowest tem- perature and shortest time quenching heat for hardening produces the best results which are prone crack. Also quenching oil rather than water generally complicated castings, especial- treating formed the machined part, which corners and changes tions. Oil quench- ing produces, (1) lb. each connecting rod (left) 500 diameters; quenched air from 1650 less distortion, From this can seen that Ar- MaSteel broached with considerable wear tools, since the loading the tool directly proportional the ma- chineability the metal. Selective hardening can success- fully applied this metal, either the high frequency induction method (such the Tocco process), the use oxy-acetylene flame for flame hard- medium such lead salt bath. Cams certain camshaft are hardened the former method sec. This cy- with current off, which allows the heat run the nose the cam, and sec. water spray quench. This pro- duces surface with minimum hard- ness scleroscope. Photomicro- the three zones, are reproduced Fig. Micrographs treated rocker arm and connecting rod are shown Fig. deg. F., reheated 1600 deg. then held min. and quenched oil, with final draw 1.5 hr. 1250 deg. Final Brinell was 4.0 mm. the right section rocker arm 100 diameters; air quenched from 1650 deg. and drawn deg. for hr. Final Brinell 4.50 mm. this part since has been found that wear occurs between the ArMa- Steel rocker and the hardened rocker arm shaft. Nitriding has been successfully ap- plied ArMaSteel. This metal when atmosphere carburizing gas and ammonia, gives shallow case approximately 0.004 in. This has been found very satisfactory such parts shifter forks and small gears. distortion from water quenching this temperature has been observed. Rockwell file hard. ArMaSteel much lower Rockwell reading resist file and wear better. low Rockwell produces file hard- ness equivalent the steel. Generally, however, minimum duce genuine file hardness. Results (2) shallow hard- ening which will add the tough- ness the core and aid straightening, (3) cracks, and (4) more uniform surface hardness and many cases higher Rockwell hardness than does water quenching. in. section Brinell 3.9 4.2 mm. held 1550 deg. for min. and then quenched oib The same section held min. 1600 deg. and quenched oil will give ArMaSteel parts can coined exact dimensions, taking reduction about per cent without crack- ing. This permits the casting parts closer dimensions. the making forgings, seven- degree draft generally allowed for ease working the dies. Solid sec- tions must machined out. Parts made from ArMaSteel have only two-degree draft, and very often holes can cored out. This means THE IRON AGE, May 25, 1939—29 ~ t S. er | RIGHT Automobile camshafts, six and eight cylinder. Formerly type 1020 steel, carburized and hardened. less machining and pronounced saving metal. Also patterns are considerably less expensive than forg- ing dies, and, nec- essary, slight changes design can readily made. The physical prop- erties ArMaSteel the softer metal, such rocker arms, are: 80,000 Ib. per sq. in. ultimate 50,000 Ib. per sq. in. yield per cent elongation in.; and hardness 187 Brinell (4.4 mm.). the harder metal which properties are: 90,000 per sq. in. ultimate 56,000 Ib. per sq. in. vield point; per cent elongation in.; and Brinell (3.9 mm.) hard- ness 241. when oil quenched and drawn, will give physical properties the neighbor- 30—THE IRON AGE, May 25, 1939 hood those shown Table Tocco hardened ArMaSteel cam- shafts have been removed from motors after 50,000 miles service and have shown absolutely wear. Selectively hardened rocker arms likewise after many thousands miles service show wear. Diesel engine pistons made from ArMaSteel are said out- last far any other metal which has been tested date. Tests made the author’s company show that ArMa- Steel pistons ran more than 700 hr. maxi- mum load aluminum iron pistons running maximum 200 hr. before failure curred, accelerated fatigue automotive connecting ArMaSteel remarkably bearing, one- half which was un- dercut 0.011 in., using load 3750 and the shaft rotating 4500 r.p.m., run considered sat- isfactory. test run with rod number bear- ings were burned out during the test but the rod continued without failure for period hr. The test this point stopped and the load increased lb. This considered very test, far more than connecting rod would ever experience lifetime service. The rod continued longer under this load, making hr. before failure occurred. This material considered satisfactory fot connecting rod automotive equipped with ArMaSteel rods. 2 3 \ a t ‘ i ¥ ‘ a the substitution important burization; (5) better tool life; (6) shaft 217 241 the Brinell test; forging ArMaSteel easier straightening; (7) better pro- 0.062 in. stock allowed for ma- found desirable develop tests which duction existing equipment; (8) chining and grinding the bearing, will detect cracks, surface imperfec- less finished weight; and (9) added eccentric and gear, and 0.045 in. tions and other defects. Final inspec- quietness motor due the damping allowed for grinding the cams. tion certain castings covered property. Applications ArMaSteel cover the electric resistance method. Cast- The cams, gear and fuel pump ec- broad field due the wide range ings are cut and etched microsec- centric are held scleroscope hard- properties. ted tions examined guarantee sound ness and are checked one hun- parts are being used the automotive, ive parts all times. all times every- dred per cent. The remainder the refrigeration and Diesel engine fields: test crankshafts, ood shafts, rocker arms, pistons, shifter forks, gears and many un- kinds levers and brackets. Pictures and many these parts -hr. sat- trations. And many test other parts requiring shock resistance with limit, good wearing quali- ties and high fatigue resistance with good machineability, are receiving considera- tion from the engi- neer possibility for ArMaSteel. Automobile ing rod, which has tested very well. present type 1035 steel forging. thing done pro- duce part which will perform well better than forging. Whenever there marked improvement automotive product, and the part can produced saving, naturally arouses the interest the automotive engineer. This has been partic- ularly true the Ar- MaSteel camshaft. was Many advantages can credited Ar- rod shaft material; ad- dies. These advantages are follows: for (1) Elimination rough machin- ing cams: (2) only one centering being (3) less metal removed machining; (4) elimination car- x “isto, . /h J one who had prejudiced interest any one the many metals that are worked cast- ing, but whose interest was the founding industry general, there were two outstanding characteristics the 43rd annual convention. American Foundrymen’s Association, held last week Cincinnati. First was the practical aspect the numerous technical papers presented the four-day meeting. Theory was wedded practice these papers manner that enabled every foundry- man there grasp immediately the influence the subjects discussed his own particular plant product operation. The second impression was the universal acknowledgment the important role that plays the development the industry. all the three sessions that com- prised the lecture course “The Microscope Elementary Cast Iron Bloomfield, J., bore eloquent wit- ness this new appreciation. This course the use the microscope was far the most popular feature the convention. Unfortunately, space does not permit dealing with Mr. Allen’s “classes” they deserve. Suffice say that the lectures were all very thought- fully prepared, were comprehensive scope, yet clothed language 32—THE IRON AGE, May 25, 1939 directed, The material used the lec- ture course has been published book form and available from AFA headquarters Chicago. Washburn Elected President Wednesday there was pause the technical sessions long enough hold the association’s annual busi- ness meeting. Henry Washburn, past vice-president the association and president and treasurer ‘of the Plainville Casting Co., Conn., was chosen president for the fiscal year, and Lester vice-president Stockham Pipe Fitting Co., vice-president the association. The five directors chosen the meeting are noted elsewhere report. Wednesday morning the an- nual business meeting was held the Hotel Gibson. Fred Clausen, presi- dent Van Brunt Mfg. Co., Horicon, Wis., delivered this year’s Board Awards his talk, Mr. Clau- sen pointed out that excessive taxes were deterrent the improvement business activity which many were looking for. stressed the need taking heed the new so- cial and political conditions which are developing today and adjusting their plant policies these changes. Wednesday evening the annual dinner was held the Hotel Gibson and the Board Awards announced ESTER SHANNON, new vice-presi- dent the American Association, vice-president Stock- ham Pipe Fittings Co., Birmingham. Mr. Shannon has long been active the work, having served director and the first chairman the Birmingham Chapter. the granting the following medals for outstanding achievement foundry industry: The Gold Medal Donald Campbell, president Campbell, Wyant Cannon Foundry Co., Mus- kegon, Mich.; the John Penton Gold Medal Harold Falk, vice- president and general manager Falk Corp., Milwaukee, and the ing Gold Medal James Allan, assistant manager industrial neering and construction tional Harvester Co., Chicago, Hurst, past president the Institute British Foundrymen, announced the dinner that the Fox Gold Medal the institute was awarded Dr. Harry National Malleable Steel Cast | | | | | | | | | 0 { | » — WASHBURN, new president the American As- sociation, president and treasurer Plainville Casting Co., Plainville, Conn. has served the association the past the capacities vice-president and director. ings Co., Cleveland. The presentation this award will made the London June 13. paper which received particular attention the convention was that Castings Co., Milwaukee, which dis- cussed the procedure for producing with tensile strength 60,000 Ib. per sq. in. commercial basis. Most discusssions high strength irons the past have involved metal With carbon content usually below per cent. The iron described Mr. Roth averaged 3.1 per cent carbon. lower carbon irons always present number casting difficulties and 43rd annual convention the American Associ- ation brought close foundrymen Cincinnati last week. Shop problems such castability, gating, melting and pouring re- ceived particular attention the numerous technical sessions, while high strength cast were again the subject hypercritical probing. were not always economically ma- chineable the smaller ings. Yet, according Mr. Roth, was able cast small gears weighing lb. each which possessed good ma- chineability characteristics. The bri- nells these gears ranged from 255 262. One the larger castings made this iron was brake drum weighing 138 This casting showed brinell ranging between 248 and 269. The cupola used producing this iron measured in. inside diameter and had 3-in. continuous tuyere with in. blocked off both the front and the rear the The charges used, with the ex- ception the bed charge, consisted 1360 steel rail, 195 Ib. return scrap (high strength type), silicon briquets and manga- nese briquets. The standard analysis this iron was 1.60 2.20 Si; 2.95 3.25 TC: 0.70 0.90 Mn; 0.12 maximum 0.09 maximum 1.50 1.75 Ni; 0.15 0.35 Cr; and 0.70 0.80 Mo. Mo, and additions are made the spout, while the Ni, the form preheated 5-lb. pigs, added the ladle. The author’s experience indicated that high temperatures were very type iron. Spout temperatures taken over period one year showed the lowest temperature 2810 deg. and the highest 2850 deg. The au- thor made one test bar which was poured 2475 deg. The tensile this bar was 49,640 against poured average temperature 2640 deg. All the tensile specimens were standard 0.80 in. A.S.T.M. bars. Heat Treated Strengths Higher Mr. Roth also investigated the influ- ence heat treatment the strength this iron. number standard bars were heated 1550 deg. F., soaked min. and then quenched oil and drawn for one hour varying temperatures. maximum tensile 91,600 Ib. resulted with 600 deg. draw, while beyond that (the investi- gation went 1000 deg. F.) the tensile strengths dropped. Typical castings produced this iron include gears, camshafts, crank- shafts, brake drums, valve bodies and refrigeration cylinders. The author stated that the machineability these castings was generally good and at- tributed this characteristic the high carbon content. the smallest cast- ings (3-lb. gears), the machining apparently more difficult than the larger castings, although the small castings through all the regular machining operations without trouble. The service life small gears cast this metal was stated four times that semi-steel counterpart. Mr. Roth felt that this iron could substituted for steel castings and forgings due “its THE IRON AGE, May 25, 2 — als the ell, ton an, \gi- 2 ced old ast- | MARSHALL POST wear resistance and good machinea- mentioned replaced steel casting. Gears Poured 2550 Deg. the discussion that followed Mr. out that the hardness the gears was quite uniform. Only approximately per cent had discarded due excessive hardness. The gears men- tioned were poured 2550 deg. and the brake drums 2700 deg. Lower temperatures resulted ex- cessive rejects the form misruns and brinells over 300. The shrinkage was said about the same ordi- nary gray iron. Silicon additions were made according the size the cast- points are added this way, while large castings only points are needed. Another phase high-test iron production gating was covered Foundry Co., Chicago, entitled duction Uniform Dense Structures High Test and Alloy Iron Cast- ings.” Essentially this paper dealt with the results experiments pouring high strength castings directly through the feeder head riser. The investiga- determine the causes shrinkage holes the gates and the adjoining metal. the course the experiments with this type gating, was ob- served that the temperature the 34—THE IRON AGE, May 25, 1939 PFAFF sand surrounding the gates and risers worked noticeable influence the shrinkage tendencies the casting. This, was felt, was due the effect the heavy flow iron heating the sand surrounding these sections and the heat the sand retarding the rate which the casting cooled. The con- ventional gates number differ- ent type castings, which shrink- age difficulties had been encountered the past, were changed and the castings were fed through the risers. was found that this change greatly reduced the number rejects and Riser Gating Used Extensively consequence his experi- ments, Mr. Scott adopted this method riser gating for the bulk his company’s dry sand work. The gating gradually changed over this method, but the effect slower pouring green sand molds study. Bushings, die wheels, rolls, gear blanks and castings are present being success- fully poured through the riser. Another interesting study cast iron was that conducted Ziegler and Northrup Crane Co., Chicago. Their paper cerned with the effect superheating the castability and physical proper- ties cast irons varying carbon contents. The base iron used their investi- gation carried 2.20 Si, Mn, 0.114 0.39 and 3.24 TC. The carbon WALLS was then reduced progressively 2.50, and 2.25 per cent irons were poured patterns the Saeger and Krynitsky type, under the following (1) superheated 3000 deg. and cast from 3000 deg. heated 3000 deg. and cast from 2800 deg.; (3) superheated 3000 deg. and cast from 2600 deg.; (4) superheated 2800 deg. from 2600 deg., and (5) superheated 2600 deg. and cast from 2600 deg. Castability Factors The conclusions drawn from these experiments were that castability creased increasing carbon content, pouring temperature and temperature superheat. The carbon content in- fluence, the authors found, presents straight line relationship. Increasing carbon from 2.25 3.25 per cent gave per cent, depending the ing temperature. Decreasing carbon, however, gave higher transverse bend, brinell hardness, tensile strength and proportional limit strengths. Higher pouring temperatures these properties, especially the low carbon ranges. Fig. space diagram presented the authors show the effect carbon content and. pouring interest note that the found that superheating cast iron high temperature and pouring lower temperature, results higher castability than pouring from 0 p Ww m al Cl t Cé t | - t SO | | m : | re be | In es. ne ig CULLING the same temperature without super- heating. Metallographic examination the irons tested showed that super- heating tends eliminate free ferrite, refine and localize graphitic flake, and break dendritic formations, thus substantiating the corresponding im- provement properties. Chromium-Nickel foundryman endeavoring add mix his regular output which will pro- vide measure heat and corrosion resistance was that presented Michigan Steel Casting Co., Detroit. The paper, which dealt with Cr-Ni irons entirely, contained very comprehensive survey Ni-Cr irons for such purposes and included much valuable data. The author pointed out that excessive pre- cipitation carbides, which the case Cr-Ni alloys are principally chromium may result los- ing per cent the chromium One way suggested avoid this dif- heulty heating the casting temperature sufficiently great dis- solve carbides, followed quench prevent their reprecipitation during the cooling period. When heat treat- ment impractical, Mr. Corfield recommended that the carbon content kept low that the extent car- bide will not serious. Where casting problems prevent do- this, the chromium may in- creased that despite the loss the neighborhood the precipitated car- COLEMAN bides there will sufficient chromium maintain the alloy passive con- dition. Mr. Corfield conducted several ex- periments which various Cr-Ni irons were subjected 72-hr. ex- posure per cent boiling acid- copper-sulphate solution and then bent approximately 120 deg. The conclu- sions drew from these are that “an alloy approximately per cent per cent having carbon con- tent within the range 0.20 0.30 per cent preferable the low car- bon content alloys for use under many service conditions and preferable from the foundryman’s viewpoint since somewhat more fluid normal pouring temperatures reason its higher permissible carbon content. This conclusion not applicable cases where the addition resistance sulphate corrosion other corrosive agents which itself particularly inert. will found, according Mr. Corfield, that increasing number consumers are now specifying the 29-9 alloy for casting requirements and many cases these castings are being assem- bled into structures with tions 18-8 and related alloys. Pro- ducers rolled products are limited the amount they can add the problems incident rolling insurmountable. Consequently they place their reliance upon low carbon content and the addition stabilizing elements such molybde- ° new directors the Association elected the as- annual business meeting Cincinnati last week are (left right}: Marshall Post, vice-president, Birdsboro Steel Foundry Machine Co., Birds- boro, Pa.; Otto Pfaff, vice- president, American Foundry Equipment Co., Mishawaka, Ind.; Fred Walls, Interna- tional Nickel Co., Chambers Culling, president, Carondelet Foundry Co., St. Louis, and William Coleman, president, Coleman Co., Philadelphia. ° ° num, titanium and columbium velop the necessary corrosion resist- ing properties. There reason, however, why the foundryman should discount his own natural advantage this respect. “The choice material for castings intended for use high temperature involves consideration two major factors, namely, resistance chemical attack and physical strength. Under oxidizing conditions minimum about per cent required plus the addition least per cent impart strength and toughness and also enhance the oxidation resisting properties the metal. high sulphur atmosphere sential.” method determining the hy- drogen content solid white cast iron direct combustion oxygen was Schwartz and Guiler Na- tional Malleable Steel Casting Cleveland. Numerous past researches into the effect hydrogen ferrous metal have indicated that this element exerts very important influence, yet, according the authors, there apparent lack knowledge the white iron may contain. Not satisfied the results de- terminations made the vacuum fu- sion method, experiments were di- rected toward developing direct com- THE IRON AGE, May 25, 1939—35 : { a ° 4 T- im nt, id, er yw bustion method. The apparatus used included combustion furnace similar the type used for carbon determina- tion, combustion tube in. long and in. inside diameter, and glass cylinder sulphur trap in. long con- taining column coarsely powdered lead chromate about long com- pletely filling the tube. The procedure follows: Weigh gram sample and burn. This the blank. Then burn gram sample and weigh. The differ- ence between and grams the water from the hydrogen contained grams. This weight then calcu- lated per cent hydrogen gram sample, viz: 18.016 2.016 Value Per cent hydrogen. Other data presented Messrs. Schwartz and Guiler’s paper was the effect that white cast iron may contain 0.0015 per cent but frequently much less and that es- capes considerable degree and considerable rate 1470 deg. and over, that the content white iron some extent related the presence rust the scrap, and that ladle addition metallic alloys, Mn, Cr, and have been invariably accompanied quite large reductions content. Pressure Plates Discussed the malleable round table meet- ing Monday, considerable interest was evidenced the use pressure cast pattern plates. Several users this type plate stated that they found that addition being generally less expensive than the sand cast plates, they were more accurate. When first using pressure plates, one malleablé melter said that had experienced keeping castings size, they were constantly running larger. cated, explained, that shrink rule CAMPBELL in. should used with the pres- sure plates, instead the conventional 5/16 in. Then turning the consideration synthetic sands, appeared that the majority those expressing opinions found that the casting finishes result- ing from its use compared favorably with natural sands. was generally agreed that the chief danger guard against using synthetic sand was excessive moisture. Too much water raises the hot strength the sand greatly and causes hot tears. Occa- sionally, was pointed out, excessive fines the sand will also cause hot tears. The amount fines the heap was adjudged deserving very close control the foundry scrap loss was kept low. Blast Dehumidifying The question dehumidifying the blast was also debated considerable ALLAN length and was obvious that there agreement among cupola oper- ators the value this procedure. Several plants have given much study the problem but none had apparent- taken any steps toward actual in- stallation the required equipment. One metallurgist stated that his ob- servations were that when the moist- ure content the blast was low, the iron mottled easier, while high moist- ure gave the castings tendency crack. thought that practice, with moisture control, would hold the moisture constantly vA about grains per cu. High Conductivity Copper Union Carbide Carbon Research Laboratories, Inc., “High tivity Copper Castings,” the industrial alloys available which strength combined with high electrical and thermal conductivity were viewed and much scattered data taining these alloys were correlated. Heat No. Writers Lab. Lab. Lab. Estimated The production alloys with over 1580 0.114 0.115 0.116 per cent conductivity was discussed 0.138 considerable detail. Most the alloys 1591 0.174 0.182 0.167 this class are the precipitation 1625 0.136 0.135 0.120 0.145 dicated, result about and 0.170 0.169 0.164 0.179 cent conductivity respectively. melting these Cr-Si alloys was recommended that bath copper Fig. 2—Results checks from outside laboratories the method determining carbon content plain carbon steel described Blosjo's paper. 1627 IRON AGE, May 25, 1939 _ | 7 : } 7 i | | | | | | : t } | FALK glass, salts such mixture sodium and calcium fluoride. add- ing was stated that the most consistent results are achieved the use pigs; recovery per cent the being usual. The use graphite skimmers and stirring rods was also advised order avoid iron contamination. The casting defects was the chief topic discussed the non- ferrous round table meeting Tues- day. One speaker warned against the improper diagnosing defects very often led still further difficulties. Among the chief causes various defects were listed core expansion, hard ramming (misruns), gating heavy casting small casting, and the absence adequate maker airplane parts throwing too much sand under the bottom board after striking off and hard clamping were frequent causes bad castings that were very hard The opinion was ex- pressed that the non-ferrous industry had not yet reached the maximum properties their alloys and that im- proved practice was necessary ob- tain these properties. Steel Melting Symposium The symposium melting was another popular feature the convention. This consisted steel foundry basic open- hearth, acid open-hearth, basic elec- tric, acid eleetric, converter duction furnace practice. Each paper Castability per cent left right are the three recipients the achievement medals awarded the 43rd convention the Board Awards: Camp- bell, Campbell, Wyant Can- non Foundry Co.; Allan, International Harvester Falk, Falk Corp., and Fred Clausen, Van Brunt Mfg. Horicon, Wis., who delivered this year's Board Awards address. CLAUSEN effect carbon content and pouring temperature cast iron its cast- are indicated this space diagram. THE IRON AGE, May 25, st- : 28 FS J igh ed, in- vas FIG. | was very comprehensive coverage and included complete details con- struction, charge, draft, etc. The as- sociation has taken these six papers and combined them which can obtained from the asso- ciation’s Chicago headquarters. An- other steel paper interest was that tric Steel Castings Co., Minneapolis, Rapid Method for Determining Carbon Plain Carbon Steels, for The instrument described Mr. Blosjo was developed mainly satis- the need for rugged but cheap instrument capable rapidly determ- ining the carbon the melt small electric furnaces. The method described consists comparing the magnetic permeability bar unknown carbon content with permeability bar known car- bon The actual magnetic permeabilities are not measured, but the effect the differences poten- tials created coils the collapse induced magnetic flux measured ballistic galvanometer. The time required make the determina- tion from the time the test sample poured until the carbon content de- termined not over min. effort check the results this meth- with those reached outside labo- ratories, samples were sent out for analysis. The results this test are listed Fig. statistical study heats indi- cated that 70.5 per cent these heats the melter knew the carbon con- tent his heat within accuracy carbon about three deoxidizing. 97.4 per cent the heats the carbon content was known within accuracy plus minus 0.02 per cent the same time. Only two out the heats varied more than 0.02 per cent carbon from that indicated the instrument. STEEL WAREHOUSEMEN HEAR HOOK DEFEND PROFIT SYSTEM HICAGO—Two steel warehouse and rep- resentatives spent two days last week the Drake Hotel Chi- cago discussing steel distribution, mer- chandising, warehouse problems and The the 30th annual con- vention the American Steel Ware- house Association, and the attendance was said the highest years. Charles Heggie, Scully Steel Prod- ucts Co., Chicago, was elected presi- dent for the coming year, and Walter Doxsey was renamed executive sec- retary, The new vice-presidents are Howard Tayler, Tayler Spots- wood Co., San Francisco, and Rich- mond Lewis, Charles Lewis Co., Burke Steel Co., Inc., Rochester, Y., was elected treasurer. Hook Private Enterprise The feature address the meeting was delivered the banquet Wednes- day night Charles Hook, presi- dent, American Rolling Middletown, Ohio, and chairman, Na- tional Association Manufacturers, who spoke “Private Enterprise and Our Standard Mr. Hook enumerated the accomplishments the free enterprise system under which live, and stated that the encourage- 38—THE IRON AGE, May 25, 1939 ment individual initiative essen- tial the success this system. save the private enterprise sys- tem, which danger many fronts, Mr. Hook advised the elimina- tion Government competition with private industry, the limitation Government expense the necessary administrative bodies and unemploy- ment relief. and the spreading knowledge among the rank and file this countrv that they may under- stand the benefits and advantages this free enterprise philosophy. Mr. Hook firm believer the ment, and told how foreign offices conduct surveys cer- tain jobs steel plants abroad and compare them with regard standard living, purchasing power, with the same comparable jobs here. Urges Wages Compared The president then urged strongly that the public made aware publication the National As- sociation “Yardsticks Industry,” which graphically compares the quantity various essentials that working people can buy with one hour’s pay this country and several foreign nations. believes that this type endeavor constitutes the best possible defense against any change our form government. final warning, Mr. Hook brought the attention the steel warehousemen, various pieces pro- posed legislation which have received little publicity, but which nevertheless point toward the elimination pri- vate enterprise and the substitution Federal control. Desvernine, president, Cruci- ble Steel Co. America, New York, presented his ideas “Obstacles Industrial Recovery and the Immedi- program. Mr. Desvernine also blamed business troubles today the constant challenge from Washington enterprise, and pointed out that much the legislation fits into pattern for new economic system. Early Tax Relief Seen The gradual increase Federal par- ticipation private business will arrested, feels, and encouragement should felt because the definite change public sentiment. Mr. Des- vernine expects tax relief for busi- ness this session congress because his opinion the president still try- ing alter the economic structure the nation. predicted future re- lief, however, stating that congress i ' | i 7 7 7 7 q | 7 7 7 7 7 7 us ~ | 3 realizing the increasing tax conscious- ness the part the public. Business taxation caused losses many places where profits otherwise would have resulted, Mr. Desvernine declared, and used his own company example demonstrate how far taxes. should confident the future, according Mr. Desvernine, believes the course opinion has changed considerably, cites example the new laws against picketing and the closed shop several states. Preparedness Urged Commitments should now, the Crucible chief still feels 1939 will better 1938. inventories were built normal levels, the backlog probably would inspire defi- stock well overstock,” said. take care this rising demand, whenever comes, imperative for the steel mills and steel warehouses work togther that they can take advantage any improvement and not caught unprepared. recom- mended progressive attitude fol- lowed the conduct the warehouse business. Adequate stocks should maintained meet this demand, when comes, speed filling orders will desired, and the warehouse should able provide this service. The objectives and the progress the mill relations commit- tee merchandising hot rolled prod- ucts was discussed Rogers, president, Beals, McCarthy Rogers, Buffalo, and chairman the committee. Study Customer’s Mind Bills, Benjamin Bills As- sociates, Inc., Chicago, Warehouse representatives require much their salesmen they did their steels. pointed out that testing salesmen, scientific pro- gram should followed when certain analysis steel being inspected certain application. discussing price cutting, Mr. Bills said the only solution, other than industry-wide cooperation, was study the mind. Something must found which will supplant low Prices the minds buyers that the sale will still made. The appeal the product, and what can particular instances what should sold, rather than the The salesmen should get the using side selling, Mr. Bills said, instead the buying side. sales talk should contain illustra- tions what the product can accom- plish just advertisements use the ap- peal the photograph aid the printed word. Further, the sales talk should planned advance and fol- low definite pattern, the sequence which should the customer buys. Norman Deuble, metallurgist Republic Steel Corp., Massillon, Ohio, was scheduled speak the metal- approach warehouse prob- lems but Mr. Deuble spent most his time discussing mill problems. pointed out that the mill must consider complaints from warehouses gage, surface, squareness, and flatness sheets. Overgrading has resulted from the competition between the con- tinuous sheet and strip mills and the older equipment, according Mr. Deuble, and the customer benefits be- cause much special treatment ac- cordingly proffered without charge, when extras should added. the opinion, the warehouse should charged for the extra flat- ness, resquaring, special surfaces, and extraordinary tolerances, now being received many cases direct re- sult this competition. Mr. Deuble believes the customer would not mind the extra cost, and that should passed accordingly. Stainless Distribution Warehouse difficulty with stainless steel can often blamed improper application and fabrication, Mr. Deuble declared, and houses consult their source sup- ply when trouble encountered. Many times, too, the metallurgical expert said, warehouses ask mills for certain steels which are very difficult not impossible ob- tain. remedy this condition, Mr. Deuble suggested more operation between metallurgical de- partments and the warehouse buyers. Inman, Pratt Inman, Worcester, Mass., his talk “Fun- damentals Cutting Costs,” produced facts and figures pertaining the cost cutting material warehouse. the first place, stated, the mill cutting schedule cannot applied warehouse, because the wide dif- ference between the two. Then, too, continued, difficulty will encoun- tered system discover the cost warehouse cutting based hourly time required cut, because some warehouses are equipped with high speed positive feed circular saws while others have slower gravity feed hack and band saws. Cutting Cost Control Mr. Inman said was more inter- ested the total elapsed time prep- aration for cutting, the removal cut pieces and the determination pro- ductive labor time, than the period required for actual cutting. Cutting costs can never secured until study made