The Iron Age 1939-06-01: Vol 143 Iss 22

cently Nt on 1€8 Op De. ter in after Ford has 0 ap- eneral eared ist “eS Or ir olume Navy lists bulk reraft dealer ertain are to the of the tools direct craft, t that FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Bditor Associate Editors Washington Editor MOFFETT Resident District Editors Pittaburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco Toronto, Ontario Birmingham Leroy ALLISON Roy Newark, VJ 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 ©. A, MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS. Vice-President JOSEPH 8S. HILDRETH, Vice-President GEORGE Vice-President EVERIT Vice-President WILLIAM BARBER, JOHN BLAIR MOFFETT, Secretary JOHN H. 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 in the Industrial Arts Index. eye Published every Thursday. Subscrip- tion Price: United States and Pos- a ( sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland I L. Herman, Chilton Bldg., Phila. H. K. Hottenstein, 1012 Otis Bidg.. Chieage H. E. Leonard, 239 W. 39th St.. New York Peirce Lewis. 7210 Woodward Ave.. Detroit Ober, 239 West 39th St., New York RON Contents 1939 Who Wants War Anyway? Handling Industrial X-Ray Film Hardening Long Slender Tools Observations Powder Metallurgy Why Special Finish? Powerful Shear for U.S.S.R. and Steel Institute Meeting Report What's New! New Designs Fixtures and Small Tools the Assembly Line Washington News THE NEWS BRIEF Weekly Ingot Operating Rate Rate Activity Capital Goods Plant Expansion and Equipment Buying Just Between Two Products Advertised Index Advertisers Copyright 1939 by Chilton Company (tne.) 112 128 131 156 7 7 -enta- ste 7 veek: from from | Lifetime Economical Production 7 | q 4 ... THE IRON AGE ... JUNE 1939 ESTABLISHED 1855 Vol. 143, No. Who Wants War Anyway preparing pass some laws with teeth them. Laws that will the profit out there ever was any profit for anybody, win, lose draw, any war. The purpose make impossible for any industrial concern expect.a profit through making and selling munitions war material Uncle Sam during state war. And the idea back that that business, and particularly big business, won't keen about pushing into war, there money it. have quarrel with the idea taking the profits out war—if there are any. And not know single business man who will object either. far business concerned—and labor, too—it will most welcome Congress can make getting into prospective war difficult and unpleasant that will next im- possible coax force into one. No, not object the purpose but the implication that business promotes war for profit. The old bogeyman. Did the force into the World War? When entered that war, few months after the reelection President Wilson the platform: kept out there were not enough munition makers America provide with ammunition and arms for five minutes active battle service. fought the war with guns and ammunition labeled ''Made didn't get started turning them out until the war was nearly over. The World War was headache American business. For one concern that earned more than its normal profit peace times, there were hundreds that suffered loss profits and that were weakened, disorganized and undermined with respect future peace-time business. More than one-half the concerns that were represented the advertising pages The Age 1917-1919 are now out business. And most them had war work forced upon them. No, business men not want war. industrialists are reluctant turn their plants into arsenals they are turn their sons into the trenches make the world safe for God knows what. There only one small group with hope profit war. And that the vocifer- ous group that looks war the golden opportunity away with the profit system and the Constitution one fell swoop. The same group that has been trying poison the public mind against the business man and the employer causers depression, unemployment and now war! Congress wants prevent American guns from shooting off abroad, may best stopping some American mouths from home. ay + q 3 Ce 7 = 3 q q 7 q Sa Letter file Inland Loyal Inland for years despite lower prices This excerpt from letter recently received from Inland customer typifies the attitude among many steel users who know Inland quality and Inland service. Using that quality and that service might well lead important economies your business. STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS RAILS TRACK ACCESSORIES REINFORCING BARS hav ent our a ent - 7 CCORDING paragraph U-68 the American Society Mechanical Engineers Code for Unfired Pressure Vessels, “all radio- graphs shall free from excessive mechanical processing defects which would interfere with proper interpre- tation the radiograph.” Certainly, would not suspected that this apparently simple single sen- tence refers one the most im- portant, complex, and least studied subjects the field metal testing and research. criticism intended here except the most friendly and constructive way, but none the less true that few inspection engineers how utterly dependent the Proper processing film are both the accuracy and sensitivity X-ray testing methods. And while this dis- cussion primarily aimed indus- trial radiography, interesting note that the same laws and processes also apply other metallographic fields, such photomicrography, HANDLING INDUSTRIAL ROBERT WOODS Physicist, National Testing Laboratories, Rochester, X-ray crystal analysis, spectroscopy, and, short, wherever photographic film used record engineering data. radiography, the actual X-ray technique employed examine weld, casting, other structure may absolutely perfect, the completed pic- ture may represent appearance pleasing the finest portrait, yet through careless improper film pro- cedures may little value scrap paper. From sheer negli- gence, defects existing the radio- graphed object may never visible the X-ray image, whereas defects purely mythical character may suddenly leap the eye. has been the author’s experience that too many industrial radiographers will through the most arduous labor insure correct exposures, only later careless their treatment the film. Photographic film, like many other scientific devices, delicate instrument and must treated such. The photosensitive emulsion consists essentially crystalline sil- ver bromide deposited gelatin and coated acetate compound base. For reasons even yet not fully under- stood, silver bromide experiences some kind change when exposed light. Whatever the change may be, far too small detected chemical methads microscopic examination, but X-ray crystal analysis does indi- cate the presence metallic silver nu- clei which increase number under exposure light. These silver nuclei themselves are certainly not photo- sensitive, but they probably play important role the formation what—for want better definition —is called the latent image. ex- posed film not really picture, but just the possibility picture; potentiality, might-be. Thus far, correct formation the latent image defect casting, for example, has been determined the factors familiar the average X-ray operator; X-ray tube voltage and current, target film distance, exposure time, etc. But whether the recorded defect will ever see the light day now solely dependent handling. The developer, briefly, chemical solution which reduces the silver bro- THE IRON AGE, June 5 | pad | | | | J. ° ° ° ° ° ° | | > Rs = mide emulsion black metallic silver the light X-ray has struck the film. Reaction between sil- ver salts and developer must selec- tive, otherwise all emulsion grains would reduced and the film surface would appear uniformly black. Actu- ally, the developer splits the silver bromide into positive and negative ions, AgBr Ag* Br-. For this reaction continue completion, silver must deposited out solu- tion onto the film. seems certain, therefore, that the substance forming the latent image—whatever that sub- stance is—is the agent which causes the silver light-affected grains deposit and form picture. Grain reduction always complete; that is, there such thing partially exposed developed silver bromide grain. Shadings and density differ- ences are due number grains reduced, not the amount reduc- tion. Photographic action is, short, response following stimulus. The stimulus light X-rays and the response the latent image which 36—THE IRON AGE, June 1939 finally image. converted into the developed When Film Fixed? Fixing solutions merely halt devel- opment dissolving all unreduced emulsion grains. This achieved two steps, (1) conversion insolu- ble halides into soluble the sodium thiosulphate the fixer, and (2) removal the double salt washing water. The question often asked, film fixed?” Perhaps wisest follow the gen- eral rule and leave the film the fix- ing bath least twice the quired for the opalescence, smoki- ness, disappear. even longer Turning now consideration some difficulties encountered indus- trial X-ray work, found that film artefacts fall roughly into two classes: (1) those which cause failure vis- ualize defects actually existing the radiographed object and corded the latent image, and (2) those which appear indicate defects where none exist. Most failure demonstrate recorded defects may traced one several types un- der-development. For instance, Figs. and are radiographs steel block which six holes varying diameters were drilled. All six holes are clearly visible Fig. but Fig. only five appear distinctly. X-ray factors both identical, but the film Fig. was tion and result one defect cannot noted. The same omission would have occurred had the film, see Fig. been immersed too short time fresh developer solution below the normal temperature. control time and temperature one the most important factors photographic work. Dust Causes Trouble Improper development may also cur dust-laden atmospheres where the developer acquires fine coating scum. This surface scum adheres the film lowered into the solution and lessens the degree duction, either over the whole surface restricted areas. One remedy for this condition dip the film momentarily clean water before mersion the developer. Somewhat similar incomplete development result from air bubbles clinging the film surface, but these can ‘ - h ot a sree! \ope? prope on extreme 4 7 7 igs. oles tly. vere was olu- low tific one eliminated film agitation Crowding film too closely tank, placing them too near the side the container, forms pockets where insufficient solution exists and produces light areas which may either simulate hide defects. For dark room work the hands should kept dry and free from dirt chemicals. Contamination fingers moist with fixer usual- produces light spots, smears, streaks. Another cause improper development partial oxidation developer films being held out the bath for examination the safe- light. This results streaks where the oxidized developer has down the film. Overdevelopment may dangerous, for too long immersion produces chemical fog the film and may obscure detail. must kept mind that there law govern- ing the form location these faded and fogged areas except the laws chance and requires but small amount either nullify the whole value radiograph. Numerous phenomena, easily repro- duced will, result the appearance defects where none really exist. where heavy object rolled over the ° ° ° various artefacts improper handling film. AAA result from snapping film while unloading the cassette; results from scratching; the re- sult heavy object rolling over the film; and with finger wet with developer. width AB. Section fogged inten- sifying screen fluorescent lag from pre- vious exposure. film, and AAA are apparently curved defects, but are reality crimp marks caused snapping the film between thumb and forefinger while unloading the cassette. The dark smudge was caused contact with finger wet with developer. All these seem easy recognize here, but when they are shaded with other shadows radiograph, their true nature some- times impossible determine. Sharpness radiographic image often spoiled elongation and smearing occurring while the film the developer. When film al- lowed stand the bath for the full time without any agitation, develop- ment decomposition products run down the surface and cause improper Therefore, films should agitated least twice during their development prevent running and chemical fog. Fluorescence Watched Calcium intensifying screens have lag; that is, after heavy X-ray exposure, they may con- tinue fluoresce for some minutes. and then developed, will found bear the fluorescent image the previous radiograph. Fig. the radiograph steel bar width AB. Part however, almost black due exposure fluorescent lag. Often this lag takes the form spot like gas pocket line resembling crack. The more transparent portions the object radiographed may over- expose the screen locally and produce afterglow image which will show subsequent radiograph. There- fore, sufficient number fluorescent screens should hand that fresh film not immediately placed cas- settes which have just been exposed. This discussion has means covered all the troubles encoun- tered the handling film for in- dustrial radiography. merely THE IRON AGE, June \ / | Tes the re- : race film im- hat can Log exposure attempt call the attention radio- graphers and engineers the fact that here exists highly important phase metal inspection work and one which consistently seems regarded simple matter rou- tine. Problems mentioned tain workers who have available the LEFT curve for X-ray film with intensifying screens. The slope the curve indicates film contrast, ability demonstrate varia- tions X-ray absorption radiographed object. Thus, viewed with bright light, will have more contrast and therefore graphic sensitivity than viewed weaker illumina- tion. RIGHT devel- opment chart, for East- man X-ray developer. Note the steepness the curve, which indicates the impor- tance the time factor for small temperature changes. finest kind equipment well those who process their film coat closets. more matter care than apparatus. has been the author’s observation that wherever film processing not regarded science, there the high- est degree sensitivity the X-ray Time development, min. 50° 60° 80° Temperature developer method can hope attain the detec- tion flaws which measure per cent more the total material thickness examined. But where the proper ray techniques are combined with careful film handling, the sensitivity X-ray inspection, based the same scale, should per cent, less, Metal Shot Improves X-Ray Photos Irregular Objects ETAL shot, some fine they float water, play im- portant part the making sharply defined X-ray photographs irregular metal objects the General Electric Co. Should radiograph monkey wrench wanted, for ex- ample, the technicians would pour tiny shot over and about it—spherical particles copper steel small that 10,000,000 them gether mere cubic inch space. The photograph then obtained has all the edges the parts the wrench sharply outlined. Had similar photo- graph been made with the wrench 38—THE IRON AGE, June 1939 simply resting the X-ray negative holder the air, the resulting picture would have very fuzzy blurred edges outlining the tool. The explanation, according Moriarty General Electric, that there such emphatic difference the absorption X-rays air and metals that the part the X-ray negative not back the metal necessarily over-exposed, with sult that the exposure “spills over” and blurs the edges the object. Again, when the object being examined has some sections emphatically thinner than other parts, there similar fuzziness The copper shot used “blocking” irregular steel object give back- ground that approaches the opacity the object, but still sufficiently opaque that the radiograph the object stands out contrast. The copper shot used must extremely fine they will “flow” freely fill all crevices, and pack only spheres will—to give homo geneous background. For some vestigations, calling for “blocking with materials other similar shot steel alloys are ploved. — | 12 | ” Cc 1 | ‘ I ; : I g | . i if a q q | 30° hardening .18 per cent in. shown Fig. has proved troublesome job some shops due warpage, which account the tool holder design, necessitated much grinding and consequent thin- ning the tool. the many suggestions put for- ward Wild-Barfield Electric Fur- naces Ltd., London, England, cure the trouble, the gadget shown Figs. 2and proved most satisfactory. The description this device ap- peared originally the journal the company. Four mild steel members, and Fig. were each shaped one edge give line contact, and bolted pairs with cast iron distance piece between. machine table vise Fig. was used house members and being dovetailed into the sliding jaw and into the stationary one. Resting the vise immediately the parting tool was make- slip which the tool was placed for air cooling removal from the furnace. The vise then was tightened and the make-up slip removed ensure unrestricted space around the tool for rapid cooling. Two air jets, and Fig. were arranged shown, and after cooling the tool was straight within 0.005 in. additional bene- fit, not foreseen, accrued method. Trouble had previously been experienced due breakage about the middle part the tool, account hardness and the fact that certain op- erations called for overhang about in. was found that tools hardened the method outlined, addition being straight, were also more less ductile about the middle part due pos- sibly the fact that the air from either end met the middle part fairly warm condition, having been heated its initial contact with the ends the tool. This would provide middle which was, consequence, less brittle, and proved ideal for overhang. Fig. parting tool, prone distort when hardened. Fig. 3—Parting tool jig, showing points application air blast. THE IRON AGE, June —— tec- Fig. 2—Jig used hold parting during air blast quenching. ness X- vith vity ame ing” ack- mely fill —as ing’ ities, ° molding parts from iron powder has apparently reached critical point its develop- ment. For the information those who have not been following the details this interesting development, might well say that the process con- sists molding iron powder into parts and articles much the same tech- nique that which employed the synthetic resin industry. The metallic powders are pressed shape, consolidated heat treatment, and are sized repressing when extra.ac- curacy desired. The economics, fine and the elimination ma- chining operations which the develop- ment has practically demonstrated have engendered large amount interest the present time. This interest iron powder mold- ing was initially generated the ex- perimental production quite large variety objects and articles chiefly from sponge iron powder which was made the ore. The pos- sibilities which these sponge iron test parts demonstrated encouraged devel- opment and research which eventually resulted the commercial production molded iron articles which fall into either one two natural classifi- cations. Those parts which were de- veloped from powder display un- usual physical structures attributes, which could not developed the 40—THE IRON AGE, June 1939 GREGORY COMSTOCK Consulting Engineer, New York normal casting and machining opera- tions, may regarded being one these types. Parts articles which can economically molded from iron powder for the actual dupli- cation cast and machined parts institute material reduction cost constitute the other. The porous iron bearing and the oil graphite loaded iron parts are ex- amples the first class these prod- ucts and the special structural effects Parts this kind were the first prod- ucts iron powder molding and were logical development the porous bronze powder bearing which preceded them. The technique which was de- veloped their production now beginning commercially ap- plied the production the solid iron part which used economic substitute for the normal products casting and machining. number such non-porous parts are now, how- ever, being made from iron powder production basis. The reduction cost and accuracy dimension which responsible for their use de- pends primarily upon the cost the iron powder from which they are prepared, and the efficiency the manipulations which are employed their manufacture. has been demonstrated that parts this kind can produced with easily repro- ducible accuracy dimension which within unusually close tolerances the strength, density and other char- acteristics the parts are the majority cases most satisfactory, the remaining factor, that the cost raw material present the most important consideration the further progress this development. With one noticeable exception, how- ever, the iron powders which are present available form and purity which suitable for fabrication into the non-porous parts and articles the latest developments, appear too expensive for this new and larger field iron powder molding. bonyl iron powder can secured price varying from 80c. $1.40 per lb. from foreign sources. Iron powder which produced the hydrogen reduction pure iron oxide quoted prices varying between 40c. and 60c. per with the possibility ad- vanced its being produced from 20c. 30c. per ultimately, new processes which are now being in- vestigated. iron powder appears vary price between and 35c. per with prices low pilot plants expanded proportions. Iron powder which sponge iron processes Sweden however, being imported country and has been largely applied the present development which are materially below the cost the other forms iron powder which have just been mentioned thal the author for one will give this product for having given the powder iron molding industry least this country major help Many Schemes Propounded has also been the 4 q 4 4 i ~ : ° ° | | | . | irther how- into es ot arger Car- per rogen and from new low hould nnage the is, that cost that credit the least ward. priv- and contemplated production schemes people who for years have been active the field, and respects their mani- fest hesitation predicting the “ulti- mate” price possibilities. Likewse, has found the Swedes being very con- servative and careful not giving any promises prices for very large tonnage production, where possibilities technical difficulties not now fully known, might upset the theoretical cal- culations. is, therefore, particular inter- est observe, that while talk about powder iron prices low dreds thousands tons, the Swedes move the reality the market and quote prices around the 6c. Ib. limit for tonnages the mere hundreds tons, without giving definite indica- tion what they can when the ton- nages required towards the “100,- reality yet fairly far the distance. The tonnage availability, character and cost the Swedish iron powder makes more suitable for the im- parts, than the three other forms iron powder which are present available. Therefore, the iron powder has been largely used, and has fact been used illustra- tion promotors further their own schemes production. There great deal difference between sam- ples from actual economically success- ful production material and “pilot plan” material. Swedish The potential demand powder now becoming apparent. arousing considerable interest and not little promotional effort being directed towards the possibility the powder from domestic ore. There are, however, number factors which will influence such project. feel sure that can conserva- tively stated that the production low carbon free sponge iron from domestic ores has been adequately in- vestigated not only the United States but the principal European coun- Curiously enough these which erection and tonnage operation very extensive and costly installations, have resulted the process being abandoned for economic rather than technical reasons each the coun- which the experiments were conducted, with the single exception Sweden. that country the process has been practiced draulic presses, such this one 4,000,000 pacity, are neces- sary for making metal powder com- pacts consider- able area. Photo courtesy Patch, Moraine Products Division, General Motors Corp. tion large scale tonnage basis for the past years. -The reason for this directly as- sociated with the fundamentals the Swedish steel making practice. They employ the sponge process for the pro- duction their steel melting base, be- cause the availability large quan- tities extremely high grade iron ore and because for their better prod- ucts they prefer the least amount refining which involves oxidation their furnace practice. Much has been said and written both for and against the principles which volved this practice. Several large volumes controversial could easily accumulated subject. The fact remains, however, that large quantities sponge iron are being and have been produced for many years Sweden, process has been thoroughly tried out and abandoned for economic reasons both this country and abroad. The end result therefore that except for Sweden there are tonnage facilities available for the production sponge iron. The sudden demand for relatively cheap but pure iron powder has, there- fore, been solved the importation that product powder form from Sweden, which alone all the coun- tries has large, going, and steady sponge iron production, which can utilized cost reducing backlog for powder produced modification this well established Swedish direct ore process. Furthermore, seems reasonable assume that for some time least the economic advantages which are incident importing this product from Sweden may very well maintained, particularly the cost the iron powder which used for powder molding im- portant consideration the develop- ment the process and its general application production parts and articles. PAGE 64) THE IRON AGE, June | q most manufacturers, the ques- tion “Why put special finish metal product?” would most elementary. The answer obviously “for decoration pro- matter fact there some justification for this question. there are still too many manufactur- ers metal products who not sufficiently appreciate the importance special finishes for sales appeal. They understand the need for coating retard rust corro- sion; they know for ADOLPH BREGMAN Consulting Engineer, New York Let take for granted the obvious fact that rust resistant coating ap- plied ferrous metal base for pur- poses protection prime method improving adding value the product. Let agree also that im- provement appearance also adds value metal article, any other merchandise. not yet widely appreciated, however, that the finish can used more generally increase the durability, add length life also tor hardness and resistance tarnish. Steel tubes are calorized for resistance oxidation high tem- peratures and resistance sulphuric fumes. Vitreous porcelain enamel one the most familiar wear and corrosion resistant finishes for con- sumer products. Long standard for kitchenware and bathroom equipment, now coming into use industry for building fronts, shipping tank lin- ings, household boiler jackets and even gasoline engine mani- folds. Aside from dee- oration, adds long life and great ease example, that tin, zinc HIRD Series Articles the Economic maintaining and cadmium and ness. nickel coatings are Aspects Metal Cleaning and Finishing used protect steel. they are not yet awake the fact that even products, manufacturers are adopting new point view toward finish. Just style has become sary consumer products, not only novelty and luxury articles but also the necessities like household equipment and kitchenware, finishes are assuming importance the most prosaic industrial products—machines and tools. longer the finish re- garded added operation and added expense—in short, necessary evil. may sometimes the last the least consideration. one the weighty factors the design. Properly chosen and applied, the finish may add intrinsic value the prod- uct, reduce the cost manufacture. 42—THE IRON AGE, June 1939 and improve the operating character- istics metal product. Present instances this kind consumer products are Sil- ver, gold, and more recently rhodium, are electrodeposited base metals which are thereby given surface precious metal, the life which, varying with the thickness the coating, may very long (in the case silverware, even genera- tion). Coatings precious metal are numerous scientific instruments, not primarily for decoration but for their special physical, chemical and Medical and dental instruments are plated with chromium not oniy for decoration, but ized but very interest- ing example the use essentially orative product novelty for utilitarian purpose the lacquer applied ash trays prevent blemishes caused lighted cigarettes and match flames. (See Fig. 1.) stances the use metal finishes for improvement product are Perhaps the clearest illustra- tions are those involving industrial chromium deposits. Their high hard- ness (about 800 Brinell) enables them effectively resist abrasion such products printing plates (for very long runs) dies and rolls (Fig. where they remain free from scratch- es, permitting the work retain smooth surface; the glass and ceramic industries for resistance elevated temperatures; the rubber q q | | a a a a | > A 1 | | ABOVE trays any shape size may protected burn- proof lacquer. These samples have been finished Maas and coal gas indus- tries for resistance sulphur and sul- phur compounds. Another advantage machine parts that the coefficient friction between polished chromium and polished steel about one-half the little extra treatment kept bright. And more often than not, they receive it. Only recently this country, al- though for some years England, have been used for wear resistance. Coatings 0.2 in. have been de- posited protect alloy and mild steel bases against abrasion. The physical properties deposits this type compare favorably with cast and rolled nickel and are con- siderably above mild steel; the part thereby given surface high grade material, ex- cellently suited for service where the attack concen- trated the sur- face. Industrial de- posits nickel are also used build steel parts worn down undersize service mis- machined under- BELOW Chromium plated machinists tools. They wear bet- 2—An example plating for improvement product. This welded steel drum, in. look better and tween polished steel diameter with 60-in. face, weighs approximately tons. The face area better care. and. sq. and has been chromium plated and polished high-lustre finish the Water- Photo from United the eombination bury plant Chromium Corp. America for mid-west manufacturer coated paper. chromium and steel shows tendency seize, gall cold weld. indirect but function special finish has come light the use electroplate indus- trial tools like machinists’ wrenches, and for the trim machine tools. (See Fig. 3.) The additional sales appeal special finish products this type probably small the buyer rule hard-headed and primarily interested full value for his expenditure terms operating efficiency. The purpose such spe- cial finishes primarily stimulate the user worker take better care his tools. The machinist will wipe his tools clean the end the day providing seems worth while. There drab piece unfinished iron; spe- pride its appearance. But plat- and polished parts seem ask for Chromium, Inc. THE IRON AGE, June ni- : al- ABOVE PLENDOR moderate cost. Per- manent backgrounds for show windows department store, Pittsburgh, made from Apollo ChromZinc, 0.012x36x84 in. These are sheets, plated with copper, and chromium. The same finish applicable steel, copper, brass and tin plate sheets, strip, coiled and flat wire. Photo Apollo Metal Works. RIGHT ROTECTION low cost base mo- terials. latex covered dipping basket, in., wire mesh. The hard black latex 0.060 thick. The basket used for clean- ing rectangular metal containers. Photo from United States Rubber Co. size error, thus reclaiming com- paratively low cost, parts which would otherwise have scrapped. Outstanding examples the im- provement product the bene- ficiation its surface are found the treatment aluminum. anodic oxidation the surface changed hard, clear aluminum oxide, highly resistant abrasion, oil, food stains, finger marking, heat and smudging, and also making excellent elec- tric insulator. Similarly, the Alzak face, making brilliant, hard and durable, for use reflectors. cently developed process for electro- plating aluminum will permit the 44—THE IRON AGE, June 1939 user take advantage the light- ness and strength aluminum prac- tically without restriction finish. This may important stimulus the use aluminum which have, the past, been held back the limits the range finishes applicable. Another important operating advan- tage effected this process the practicability soldering nickel plat- aluminum articles, whereas former- ly, the bare aluminum could not joined this method. These few examples illustrate the fact that finish may value product improving its operation under service conditions, 4 lengthening its life and also the indirect, though important, inducing better care its handling. many cases such finish may add little the cost. But, the light the improvement not hidden under bushel; made clearly evident by, the same time, ing the appearance the will not only justify slightly high- price but will also make the better price obtainable. Lowering the Cost special metals alloys almost any de- sired properties can obtained. But this practice necessarily limited | > = : 1 economic factors. Hardware made gold would and would last forever, but one could afford buy it. Similarly (for more rational example), lighting fix- tures solid bronze have permanency and beauty but also comparatively narrow market. Consequently, most cast lighting fixtures are made the zinc, aluminum alloy, cast molds, plated and RIGHT design and finish with inexpensive materials. ing fixture made extent metal (zinc 95, alumi- num plated and finished. Photo from Lightolier Co. ° ° ° BELOW superimposing surface material. This installation Robertson Bonded Metal (with walnut veneer surface), used panel the library the Eye and Ear Hospital, Pitts- burgh. The composite consists steel, cloth and wood, permanently fused together. The steel core sheet coated with soft metal, low melting point, after which layer cloth fused the sheet means heat and pressure. Tiny metal penetrate and interlock with the cloth fibres. The wood veneer applied with phenolic resin ad- hesive the cloth. The complete assembly can cut, stamped. bent thousands varieties. They are low price but they are fully good for the purpose the most expensive materials. Moreover, their beauty re- siding the design and the surface, may just great they had been made gold. there bad taste attached the use cheap base materials; there only good sense. metal finishes is, therefore, effected the use inexpensive base and improving the surface special treat- ment covering with thin coat the more expensive material which has the better properties desired. This coating may take the form plating any large variety metals and colored oxidized finishes; may lacquer, lacquer enamel synthetic coating any literal- hundreds designs and colors; may even very inexpensive finish like lithographing. many cases also, possible use pre-plated sheet and strip metal which already has the desired surface, requiring little finishing work the fabricated arti- cle. comparing the cost bare and specially finished metals, must borne mind that even the “stain- less” resistant metals re- quire polishing presentable for consumer use, and that polishing the most expensive operation the metal finishing cycle. Coatings, elec- trodeposited, sprayed, dipped, brushed, and surface treatments are gen- erally cheap and easily applied (ex- cept the cases the precious met- als and perhaps isolated examples special enamels lacquers which special accounting must made for the cost materials). The lighting fixture mentioned pre- viously only one example the use cheap basis metal which, to- gether with the finish, costs less than expensive basis metal. Another illustrated the classic story the automobile manufacturer, who, the days when cars had prominent radi- ator shells, balanced the cost pol- ished stainless steel versus cold rolled plate, and found that the plated shell would cost him about $2.40 less. (He then chose stainless steel—no doubt for perfectly valid reasons his own —but that another Another literally shining example the light reflector. The first pre- requisite material with high re- Other permanency, freedom long life and perhaps above all, since they are used such huge quanti- ties, reasonable cost. Using fine ex- pensive materials, the manufacturer restricts these materials the surface his And although may use porcelain enamel Alzak silver even rhodium, using cheap basis metal and restricting the expensive material very thin surface finish coat, can produce fine, serviceable, high quality prod- uct reasonable price. hidden but nevertheless present factor reducing the cost manu- facture resides the practicability producing wide variety appear- ances, colors and designs, with the perhaps only one, steel, thus keeping inventory down the lowest figures. cited almost forms plated Instances could without end. All 40,000 Ib. Unalloyed Gray Iron unalloyed gray cast iron with tensile strength 40,000 Ib. per sq. in. and Brinell 215 and highly resistant the corrosive effects most chemically active waters, has been developed the Pomona Pump Co. Pomona, Cal. This iron, called Pomoloy, cast production basis the company’s pump parts foundry and was devel- oped overcome the secondary cor- rosion frequently found deep well well dispersed, nodular graphite and said have excellent resistance impact, shock and vibration. the cast condition the iron has smooth, close grained skin highly resistant corrosion. Pomoloy machines with 46—THE IRON AGE, June Developed Pomona Pump Co. cutting action, similar malleable iron steel, and the resultant surface capable being highly polished. The iron can hardened heat treatment the oxy-acetylene pro- cess. Pomoloy cools higher tempera- tures than ordinary cast iron and re- HOTOGRAPH spring cut from stand- ard transverse test bar Pomoloy, minus any special the resiliency and the high ma- chineability the iron. This cast iron spring can bent into U-shape and stretched compressed and will resume its original shape. steel; all forms protection rust—chemical, paint, hot galvanizing, tinning, and lead coating; metal ing, sherardizing, rubber coating, are methods using cheap basis metal and coating with material which has special properties suitable for special purposes—at cost manufacture. Briefly, therefore, the reasons for putting special finish metal prod- ucts may summarized (A) add value the product because (1) better operation ser- vice; (2) longer life, resistance wear corrosion both; (3) im- proved appearance improved style. These factors apply not only prod- ucts for general public consumption, but also industrial objects which improved finishes would induce better care the prod- uct machine, and better operation, because the pride the operator his machine tool. The slight ad- ditional cost can easily recovered the sales price the value made evident improved appearance. (B) lower the production cost (1) the use cheap basis metal which, together with the finish, would cost less than basis metal alone. quires modification the usual gray iron gating and feeding practice. The iron produced two grades —Pomoloy C-2 and Pomoloy Both these irons come under A.S.T.M. specification A48-36, the C-2 type falling Class and the C-3 Class 50. Tests the C-2 grade show tensile strength excess 40,000 per sq. in., transverse test (1.20 in. round bar in. centers) 2850 Brinell hardness 215 and deflection over 0.24 in. : | | 1 : } | & . POWERFUL SHEAR FOR ESIGNED and built the plant the Thomas Machine Mfg. Co., Pittsburgh, large plate shear, believed the world’s larg- est, has been consigned Machino- import the U.S.S.R. for use Soviet plate mill. cast steel construction through- out, the machine weighs nearly 500,- 000 and has capacity for shear- ing plates in. thick 162 in. wide one stroke—shearing steel 60,000 Ib. per sq. in, tensile strength. The main shaft alloy steel and driven from both ends means herringbone gears, completely enclosed and running oil. gear drive operated magnetic clutch. This method driv- ° ing permits the ram stopped any point the stroke, also The gear drive operated means permits the ram down. magnetic clutch which com- bined with the brake. This method driving permits stopping the ram any point of-the stroke and also per- mits “inching” the ram down, de- sired. this method push-button, only the flywheel shaft and the motor are running, when the machine idling, the gear train being rest. The flywheel shaft mounted Timken bearings. The flywheels are made steel slabs turned all over insure perfect balancing. The ram balanced means air cylinders. The holddown shown the accom- panying photo is. operated air, but can also controlled hydraulically. The operation the holddown syn- chronized with the movement the ram. view the plate shear. weighs close 500,000 and has capacity for shearing plates in. thick 162 in. wide. For handling heavy plates, casters mounted springs are provided the table the machine. These casters are set carry the material slightly above the lower knife. The special feature this machine that the knife the ram ar- ranged that can quickly changed splitting slitting plates. nor- mal position, the machine will shear plates 162 in. wide. For shearing raising and lowering screws, driven motor which will permit setting the plate quickly any angle. THE IRON AGE, June uct er- ‘or ‘ RNEST WEIR, chairman the National Steel Corp., was elected president the American Iron and Steel Insti- tute, succeeding Tom chairman the Republic Steel Corp., who had servedtwo years. Twonew vice- presidents were elected William Irvin and Block, who recently retired. They are Ben- jamin Fairless, president the United States Steel Corp., and Frank Purnell, president the Youngstown Sheet Tube Co. the presidency the institute now limited one term two years, the new vice-presi- dents, turn, probably will succeed the presidency after Mr. Weir’s term. The institute medal was presented Whiting, president the Alan Wood Steel Co., Conshohocken, Pa. Attacks the New Deal for its policies featured both the morning ses- sion and the banquet the evening. Tom Girdler, whose published this issue substantially full, warned against continuation excessive Government spending, high taxation and the Wagner Act its present biased form. declared that “the New Deal philosophy produc- ing poverty” retarding normal in- dustrial revival. United States Senator Miller Ty- dings Maryland, who was the cipal speaker the banquet, charged that the present policies the New Deal are leading the country nomic slavery.” presented eight- point program for Government econ- omy, business revival stabilization. declared that the guise improving the condition the people, the National Govern- ment actually squandering their sub- stance and prolonging the misery the masses.” Several references were made the recent wave price cutting flat rolled products. Mr. Girdler said hoped that last meeting would mark the beginning more orderly marketing steel. the morning session Benjamin Fairless read paper “Standard- 48—THE IRON AGE, June 1939 ization the Steel Arthur Roeder, chairman the Colorado Fuel Iron Corp., who had prepared paper “The Management Factor Labor Relations and Public Rela- tions,” was unable deliver per- son because illness. His paper was read Walter Tower, executive secretary the institute. The afternoon technical session was under the chairmanship Charles White, vice-president Republic Steel Corp. The papers presented were follow: “The Training Metallur- Bradley Stoughton, Dean Engineering Lehigh University; “Problems the Manufacture and Use Steel Products the United States,” (abstracted the May is- Lose, vice-president nois Steel Corp., with discussion Quincy Bent, vice-president Bethle- hem Steel Co.; “The Manufacture, Sale and Use Steel Products Great James Henderson, deputy-chairman ham Steel Co., Ltd., London, England; “The Value Electric Arc Welding Design and its Limitations,” Isaac Harter, Hodge and Glen Schoessow, all Babcock Wilcox Co., with discussions Snyder the United States Navy, and Hollister, Dean the College En- gineering Cornell University. Copies these papers may ob- tained from the institute. Girdler Discusses Effects Political Events Business ESPITE the which the steel industry, common with all business, facing, Girdler said his ad- dress president the institute that had not lost faith the future this country the future the steel industry. “We have had years depres- sion and subnormal production, and convinced,” said, “the country ready for long period replen- ishment, rebuilding, and expan- sion which steel ready share. With least some temporary abate- ment the war scare Europe, all that needed get industry under way the removal the brakes upon business expansion and employment. “If that were done, convinced that the national income would speed- ily rise more adequate levels. Only the people themselves can compel the changes necessary restore prosper- ity and preserve the country’s institu- tions. believe their course already decided, and promises well for the ultimate future America.” Answering the insinuations have recently been heard that many business men are “war mongers,” Mr. Girdler said: “The steel industry prays for peace for the world and above all for peace BENJAMIN FAIRLESS - q - q ] { = — > ‘ | 7 | | | | : f | | | for the United States. Some people believe that steel would profit from war, and would There basis for any such belief. War brings real prosperity for the steel industry. Any temporary profits from forced activity plants during the World War were largely dissipated the need readjust the industry peace time products and the period economic distress which was the aftermath the war. “Of course the midst world that arming the teeth neces- sary for this country provide for its own defense. But how much bet- ter would Europe would solve its difficulties and turn the billions dollars annually now being spent arms into avenues productive enter- prise. The steel industry vastly pre- fers the making plowshares rather than swords, “Apparently there are some this country who would send American sol- diers the battlefields Europe, help put down dictators and save the world for democracy all over again. wonder they have thought through FRANK PURNELL the consequences our joining another foreign war, particularly with the Government under the influence the economic ideas now pervading it. certain night follows the day, while were fighting crush dic- tatorships abroad would en- trenching one home. “Our participation another World War would mean death blow in- dividual freedom the United States. Life would rigorously regimented. Industry would lose the last vestige private control. Labor would take or- ders from Government bureaucrats. And when the war ended those con- trols would not soon lifted. The economic and political bankruptcy the country would complete. Per- petuation dictatorship would ap- pear the only answer. Road Leads Dictatorship “Even now peace times while our Government berates the dictatorships abroad, persists domestic policies leading straight down the road dic- tatorship the United States. Many the measures most open attack under dictators have been adopted and are full effect here. These mea- sures not only are checking business expansion but they are carrying the United States rapidly toward changed form society, some variety collective state. WEIR “Consider, for example, the rapidly pyramiding increase the share national income under control the Government; the mounting Federal debt and deficit spending; the stifling private enterprise unsound tax- ation; the persecution industry through unfair labor laws; the reck- less interference with industry reg- ulatory and the evils carelessly devised social security legis- lation, “To this list might added, among many others, both the open and veiled attacks upon the profit motive busi- ness. upon the profit motive comes from those who would destroy the profit system because essential private enterprise which they would undermine dominate. comes from those who, living apart from realities, have convinced themselves that profit for industry comes only through exploitation labor. comes from those who for reasons political opportunism would hold profits flag incite class hatreds. “Some months ago the country was filled with talk changed front Washington. The Administration was start great program business cooperation—all aimed confidence, stimulating industry and trade, and increasing employment. Well. are still waiting for THE IRON AGE, June on, ace ace ‘ wee, — start. According all reports there was battle royal among the inner circle the Palace guard, with the extreme left-wingers routing the mod- erates, and the cooperation program was cancelled. “And now, according all reports, another kind program being de- vised for industr