The Iron Age 1939-07-20: Vol 144 Iss 3

E. WRIGHT Managing Editor Mochinery Bditer FRITZ FRANK President VAN DEVENTER Editor MILLER Art Editor ROWAN News Editor WINTERS FINDLEY Editor Emertius LIPPERT Metallurgical Editor Associate Editors Washington Editor Resident District Editor< T. CAMPBELL Pittsburgh JAMES Cleveland BINGHAM Chicago W. FF. SHEKMAN Detroit Editorial Correspondents London, Bngland Cincinnatt FRAZAR Boston MEYER Milwaukee Hamburg, Germany Contents 1939 CHARLES Post San Francisco SANDERSON Toronto, Ontario ALLISON Newark, N. J. TURNER, Jr. Ruffalo ASA ROUNTREE, Birmingham toy EDMONDS St. Lowis Reserved Seats Decarburization Steel Owned and Published by Oven Replaces Air Drying Bright Hardening Small Parts Ceiling Wages, Floor Hours CHILTON COMPANY (Incorporated) Air Conditioning Woodward Blast Furnace Bismuth for Fusible Alloys 239 West 39th New York, Publication Office Chestnut and 56th Philadelphia, Pa. Steel Castings Aircraft OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President STEVENS, Vice-President JOSEPH HILDRETH, Vice-President GEORGE H. GRIFFITHS, Vice-President EVERIT B. TERHUNE, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOUN VAN DEVENTER, JULIAN CHASE, THOMAS L. KANE, CHARLES 8. BAUR, G. CARROLL BUZBY, P. M. FAHRENDORF Finishing Room Control Canadian Ore the Assembly Washington News THE NEWS BRIEF Statistics Metal Working Activity Weekly Ingot Operating Rate Rate Activity Capital Goods BAUR, General Adve Manager DIX, Manager Reader Service Plant Expansion and Equipment Buying 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 copy, cents. Cable Address, New Industrial Literature “Tronage, N. Products Advertised Just Between Two Index Advertisers ADVERTISING STAFF Kmerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Blidg., Phila. H. K. Hottenstein. 1012 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 239 W. 39th St., New York D. C. Warren, P. O. Box 81. Hartford, Conn Don F. Harner. 1595 Pacifie Avenue, Long Beach, Cal Copyright 1939 by Chilton Company (Inc.) ke 3 Uniform Results ... Lower Costs with Ryerson Certified Alloys You can reduce failures—eliminate spoilage and get better results less time with Ryerson Certi- fied Alloy Steels. They are from selected heats steel that meet ideal specification—a “specifica- tion within assures uniform response heat treatment. All Ryerson Certified Alloys are analyzed and tested advance. Special data sheets showing exact chemical analysis, grain size, cleanliness rating, and results actual heat treatment tests, are prepared and sent with every shipment. You know exactly what you are getting. Your heat Principal products stock for Im- mediate Shipment include— Bars, Structurals, Plates, Iron and Steel Sheets, Tubing, Shafting, Strip Steel, Alloy Steels, Tool Steels, Stainless, Babbitt, Welding Rod, etc. 24—THE IRON AGE, July 20, 1939 treater does not have test. takes chances. Spoilage eliminated and sound, dependable jobs high accuracy and uniformity are secured. Ryerson has large and complete stocks these selected identified alloy steels. They cost more and quick shipment assured. Ryerson Certified Steels also include carbon, tool and stainless steels that meet definite quality standards. They offer many advantages steel users. Let tell you the complete story. Write for booklet. Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. - ... THE IRON AGE ... JULY 20, 1939 ESTABLISHED 1855 Vol. 144, No. Reserved Seats HIS strike certain members the WPA fraternity against the Government's program relief for the unemployed reminds story. Once upon time there was extremely charitable family, and one fairly well-to-do, that lived the outskirts certain town. The heads this family, Samuel Jones and his wife Samantha Jones, familiarly known Uncle Sam and Aunt Samantha, had experienced the vicissitudes life and therefore were sympathetic with the handicapped and the unfortunate. Uncle Sam had had make his way dint strenuous labor against great odds, and his wife, Sa- mantha, had had count and conserve every penny make ends meet. However, exercising the virtues frugality, they had arrived comfortable competence. spite their comparatively affluent circumstances, this couple could never for- get its humble beginnings. Nor could they forget lose sympathy with the less for- tunate. they resolved that long they were position so, application for help from people distress should unheeded. result this determination, their home became the mecca the unfortunate who needed meal night's lodging. one was turned away. With Uncle Samuel and Aunt Samantha, ask, was But with one qualification. That qualification was this. Uncle Sam firmly believed that what the unfortunate needed was not charity, much the opportunity earn Free meals, there- fore, were taboo. All comers were welcome sit down hearty meal enjoy night's lodging, provided they were willing chop certain amount wood. This system worked very well, one day came sojourner who requested meal: Aunt Samantha started explain him the conditions set down Uncle Samuel for earning meal ticket. But the applicant interrupted that chap. sitting the table common answered Aunt Samantha. much wood did have inquired her questioner. it's any your answered Aunt Samantha, was that remarked the newcomer, should get dinner for chopping nof more than four, since when employed earned four times much per hour that What Aunt Samantha said this chap can easily imagined. And the moral this story that there are reserved seats life raft, except for women and chil- J | Fic >» the average many hundreds shop experiences holds true, you can make important savings machining costs substituting Inland Ledloy similar analysis for the steel you are now using. The economy worthy test. probable that you can save from $10 more than $50 per ton every ton steel machined. Others are doing it. You can increase machining speeds 30% 100%. You'll get 100% 300% longer tool life. you can use steel higher chemistry without increased machining cost. special equipment change any process required, for, aside from its superior machinability, Inland Ledloy has the same properties ordinary steel. ost SHEETS STRIP BARS PLATES FLOOR PLATES STRUCTURALS PILING lead This saving machining time was reported parts manufacturer, who also adds: “The finish with thi increased machining speed was excellent.” 918 1,330 PARTS PER HOUR appliance manufacturer obtained this increased substituting Inland Ledloy 1115 for SAE-X1315. Inland Ledloy can ordered any standard analysis any rolled form through your nearest Inland office, cold finished form from your cold finisher. For information call the nearest Inland office, write for new Inland Ledloy Bulletin No. 11. REINFORCING BARS RAILS TRACK ACCESSORIES its los: res sur que whi far sive met diff ava con The trib evic of t ditic 7 SALEM, OHIO this, the first section two-part article, the author describes the effect atmosphere, temperature and type steel oxida- tion, and all factors determining decarburization steel open furnaces. Next week, specific data will given decarburization various types steel heating furnaces. the most important prob- lems modern steel making the decarburization when heated for the various steps its manufacture. The decarburization steel may simply defined the loss carbon from the surface the result reaction with thé hot gases surrounding the steel during heating cooling. But from that point the question anything but simple. The large number complicating factors which affect the carbon loss have far prevented the compilation suffi- cient complete data for comprehen- sive study the subject. The develop- ment positive control yet the stage where available information scattered and confusing, much the situation some branches medical research. The purpose this article con- tribute small amount additional the more important heating proces- the steel industry, particularly guide the form which ad- ditional data can added order make comparative and consequently more useful. Laboratory research has established the fact that certain gases are defin- itely decarburizing steel that others are carburizing their action; and that others are practically neutral steel elevated temperatures. Prog- ress has also been made determining the stability various gas combin- ations contact with heated steel various analyses, but much work re- mains done this field. With some definite information av- ailable, the next step the practical application, and this phase that the writer primarily interested. Until recently all furnaces were open- fired and the factor scale (oxida- tion the iron content) could counted upon assist the reduction decarburization limits allowable that time, actually removing the decarburized surface the form iron oxide, scale. Now there are important number clean, bright-heating furnaces utilizing protective atmosphere prevent ox- idation the iron. This has been de- veloped with comparative ease, but the difficulty has been increased many steels, and this, together with more rigid specifications, has constituted new major problem for the makers and users steel. discussing the problem the plan consider the open furnace and the protective atmosphere furnace separately, and this method will ad- hered the following discussion. Open-Fired Furnaces Open furnaces are those which the flue gases resulting from the com- bustion the fuel are direct con- tact with the steel during heating and cooling. For the entire range fuels, these flue gases consist varying per- centages carbon dioxide, water vapor, and nitrogen when the theoret- ical amount combustion air sup- plied and perfectly mixed with the fuel. Practically, the atmosphere also includes either oxygen from sive supply air, carbon monoxide and hydrogen resulting from defi- ciency air, all them resulting from poor mixing air and fuel. The first atmosphere from excess air known “lean” oxidizing which correct, while the atmosphere from deficiency air commonly called “rich” reducing, which not cor- rect because contact with steel the usual reducing atmosphere will dissoc- THE IRON AGE, July 20, 1939—27 q d | x 7 7 hotive or mplet 2 ars release oxygen and the and Murphy has established the relation between the atmosphere open furnaces and the oxidation steel. Using city gas furnace temperatures about 2000 deg. F., they have shown that per cent (about per cent theoretical combustion air) the reduc- tion scale formed was not notice- able. From that point per cent the flue gases (63 per cent com- plete combustion) there graduai reduction scale formation, and from there 16.5 per cent (55 per cent theoretical air) the scale formation drops rapidly practically zero. For practical purposes then, scale cannot controlled any extent, because beyond per cent (7.7 air- gas ratio for natural gas) temperature cannot satisfactorily maintained open furnace. The same investigation Jominy and Murphy has also contributed in- formation the effect temperature and steel analysis oxidation, burization. Their tests have shown that for SAE 1015 steel heated the usual “neutral” atmosphere city gas fired furnace, the loss weight per 100 sq. in. exposed steel about follows: 2000 deg. the loss Ib. per 100 sq. in. exposed and 2400 deg., the loss 0.32 per 100 sq. in. exposed area. For the same neutral atmosphere gases) and common temperature 2300 deg. F., the relative scaling rate for several standard steels, cated the loss per 100 sq. in. follows: For SAE 1030 steel, the loss 0.32 Ib. per 100 sq. in. ex- posed area for SAE 1050 steel, the loss 0.29 for SAE 1015 steel, the loss 0.24 for SAE 1090 steel, the loss 0.19 for high speed steel, the loss 0.38 for SAE 4140 steel, the loss 0.27 for SAE 6145 steel, the loss 0.26 for SAE 3130 steel, the loss 0.19 Ib.; for SAE 2320 steel, the loss 0.19 and for SAE 4615 steel, the loss 0.18 per 100 sq. in. exposed surface. The various factors which affect the formation scale open furnace include The fuel used, which determines the chemical analysis the furnace at- mosphere, particularly amounts active oxidizing compo- nents (oxygen, CO,, and water vapor). 28—-THE IRON AGE, July 20, 1939 TABLE Decarburization Soaking Pits Regenerative Pit, Natural Draft Producer gas in. water negative 2150 2335 deg. FACTORS (see text) (1) Fuel (2) Furnace pressure (3) Temperature (4) ratio oxidizing (5) Type burner none (6) Per cent area increase (7) Time pit, hours (8) Grade steel, SAE DECARBURIZATION, INCHES Carbonless 0.000 0.000 Pronounced 0.010 0.017 Slight 0.010 0.013 Actual total depth 0.020 0.030 Total depth corrected 300 per cent area increase 0.038 REMARKS Ingot size, inches Billet size, inches 8x7 6x6 All cherry red ingots when charged. pressure, which determines whether not free air drawn into the furnace and what quantity. Temperature the steel ously discussed. Air-gas ratio, which affects the an- alysis the atmosphere. Type burner, because the degree mixing affects the atmosphere pro- duced, and because the different burner block temperatures with various burners affect the extent dissoci- ation. Variation and tightness scale with different burners are recognized but correlated data are available. Time temperature. Analysis the steel. These factors are common all open fired furnaces and constant ef- forts are made control least some them all heating processes. In- dividual solutions are necessity ar- rived at, but any extensive collection stage development. addition these common factors, there are others found special cases, including the use covers and protective com- pounds. The amount oxidizing gas which comes contact with the steel unit time obviously important the results obtained, but cannot con- trolled most cases, since function the heat required the furnace. The use sheet alloy covers (not sealed retorts boxes) for tem- Regenerative Pit, Forced Draft Producer gas 0.05 in. water positive 2150 2350 deg. slightly oxidizing none 7.7 6.1 6.5 9.8 9260 1065 9260 1065 0.000 0.002 0.000 0.000 0.002 0.027 0.007 0.008 0.010 0.006 0.003 0.014 0.007 0.010 0.010 0.010 0.041 0.025 0.020 0.020 0.016 0.010 0.075 0.046 0.025 0.029 peratures below 1800 deg. deflects large part the gas away from the steel and effective reducing scale formation where they can satisfac- torily applied. Compounds which the steel pieces are dipped before heat- ing are also effective but are economi- cal only limited number cases. With the foregoing outline scal- ing, the oxidation iron, mind, the parallel phenomenon zation, the oxidation carbon, open fired furnaces can now con- sidered. Each reaction closely asso- ciated with and enormously compli- cated the other, that study decarburization impractical without understanding scaling. Both re- actions are affected the same tors varying degrees, and the net decarburization, after removal scale, determined the relative speed reaction the result the combina- tion factors present any repetition these factors, they affect decarburization follows: (1) Fuels—It known that CO, and the combination hydrogen and water vapor are decarburizing steel, and since the amount these gases produced per unit heat the fuel varies with the different fuels, fol- lows that the decarburizing will vary for these fuels. Calculations the quantity water vapor and CO, the flue gases from the perfect combustion sufficient fuel 1,000,000 B.t.u. show the — | ‘ { depth decarburization inches Time soaking pits, hours tion soaking pits. Note that the decarburization corrected 300 per cent area increase. The improved results obtained can accounted for only the improved control furnace atmosphere with forced for fuels which follow. The practical comparison fuels will further discussed under specific ex- amples. The cubic feet water vapor and carbon dioxide per 1,000,000 B.t.u. for coke water vapor and 2180 cu. ft. carbon dioxide; for bituminous coal, 685 cu. ft. water vapor, and 1930 cu. ft. carbon dioxide; for fuel oil, 1295 cu. ft. water vapor, and 1530 cu. ft. carbon dioxide; for tar, 712 cu. ft. water vapor (steam atomizing adds about 133 cu. ft. water vapor), and 1870 cu. ft. carbon dioxide; for butane, 1560 cu. ft. water vapor, and 1248 cu. ft. carbon for natural gas, 2020 ¢u. ft. water vapor, and 1120 cu. ft. carbon dioxide; for city gas, 2394 cu. ft. water vapor, and 1048 cu. ft. carbon dioxide; for coke oven gas, 2230 cu. ft. water vapor, and 1058 cu. ft. carbon dioxide; for raw producer gas, 950 cu. ft. water vapor, and 2050 cu. ft. carbon dioxide; for anthracite gas, 1213 cu. ft. water vapor, and 1861 cu. ft. carbon dioxide; and for blast gas, water vapor, and 3080 cu. ft. carbon dioxide. (2) Furnace pressure—It has been established that free oxygen from the (as contrasted with nascent oxy- gen from combustion) almost decarburizing wet hydrogen and more active than CO, removing the carbon from most steels. The differ- ence between this free oxygen air entering the furnace through doors, cracks, and other openings, and the nascent oxygen resulting from ex- cess air supplied through the burn- ers just one the many confusing facts relating this subject. The only method preventing the entrance this free oxygen establish and maintain pressure the furnace which slightly higher than atmos- pheric pressure all parts the furnace. This pressure should about 0.01 in. water the lowest point the furnace and maintained controlling the outlet flues the fur- nace suit variations the fuel supply. This may accomplished some cases simple connection between the flue damper and doors control valves, but most instances the standard automatic furnace pres- sure control systems are the best solu- tion. general, the tendency decarburiza- tion increases with cause the reaction between the carbon and the gases the furnace in- creased increase temperature. However, the oxidation iron also increases with temperature, and there are cases where reduced decarburi- zation after removal scale found with higher temperatures, because the scaling has been increased greater extent than the decarburization. third phenomenon—the diffusion carbon from unaffected areas decar- burized areas—also affects result, and the effect temperature this factor not yet well under- stood. (4) ratio—The ratio air gas supplied the burners open furnaces has large affect the resulting decarburization because directly affects the analysis the furnace gases. With the so-called re- ducing atmosphere resulting from deficiency combustion air, pari the hydrogen the fuel oxidized water vapor and the remainder appears its original form, with resulting wet hydrogen which the most active all decarburizing com- binations. The carbon the fuel appears both carburizing and most cases that decarburizing combination. With excess air, all the hydrogen appears water vapor, less active decarburizer than when the presence hydrogen, and all the carbon combined Nascent oxygen present which in- creases the formation scale. general, indicated that the net decarburization after removal scale the minimum for most steels when the air-gas ratio the slightly oxidizing side. (5) Type Burners Premix burners with thorough mixing and high flame temperatures consistently produce the lowest decarburization the author’s experience, probably be- cause more complete combustion the fuel before contacting the steel and because the dissociation com- bustion gases the higher burner port temperatures. Similar results are also indicated from furnaces which are designed with hot combustion chambers (indirect fired furnaces) for the same reasons. (6) Per cent reduction after heating —For most higher temperatures the problem decarburization arises connection with the heating for rolling drawing which the section the piece heated reduced forming. This reduction increases the surface the finished piece and correspond- ingly decreases the thickness the decarburized skin formed heating. Decarburized depth finished pieces cannot properly compared unless corrected for this increase area each case. For example, the area the sides 4x4-in. billet in. long 192 sq. in. this billet rolled into bar in. diameter, the length be- comes 245 in. and the new area the surface 770 sq. in. The increase area (or decrease depth decar- burization) will 400 per cent. THE IRON AGE, July 20, 1939—29 other words, the depth decarburiza- tion in. diameter round when rolled from 4x4-in. billet will diameter round from the same billet, and about one-fourth that the billet after heating but before rolling. low temperature processes for an- nealing, hardening, normalizing, etc., the factor reduction increase area usually not involved. (7) Time Temperature—Decar- burization always increased greater length time temperature, since the nature the reactions in- volved such that they are gradually progressive with time. shown test results discussed, the analysis the steel has great affect the amount decarburization under any conditions, which fur- ther complication because the amount data necessary for any broad under- standing the subject increased. will long time before any correlated understanding the effect the many other factors will definitely known for the wide range steels from the low-carbon the high-carbon steels, high speed, various alloys and alloy combinations, and stainless steels. With this outline involved the decarburization steel, and with the simultaneous scal- ing action some extent understood. now possible more intelligently examine certain scattered evidence concerning decarburization differ- ent furnaces, which the author has collected over considerable period time. These data were obtained fur- naces which may outlined lows: For soaking pits, heat ingots, fired with raw producer gas. For batch-regenerative nace, for heating billets, fired with raw producer gas, coke oven gas and natural gas. For batch-burner fired furnaces, for heat- ing billets, fired with coke oven gas, natural gas, coal, and fuel oil. For continuous pusher furnaces, for heat- ing billets, fired with producer gas, and natural gas. For batch-car type furnaces, for anneal- ing, fired with coke oven gas and natural gos. Data collected for soaking pits in- cluded results from four grades steel, each heated standard regen- erative, reversing pit with natural draft, and identical pit except for the provision forced draft from low pressure fan which makes possible maintain slight positive pressure the pit all times. The fuel was producer gas all cases, and all the results tabulated Table were checked several additional tests. The figures indicate the very considerable effect the furnace pressure preventing the infiltration free air into the furnace. All other factors remained the same each case, and the improved results de- carburization can accounted for only the improved control fur- nace atmosphere with forced draft. Fig. shows the data this table graphical form. Ed. Note: Next week the author will present data de- carburization all the other types furnaces mentioned above. Reel Drums Controlled Independently accompanying illustration drums driven gearmotors, the Superior Steel Corp., replacing former one driven motors coupled speed reducers. There has resulted the use minimum floor space and low cost installation and operation. many six coils are 30—THE IRON AGE, July 20, 1939 drawn through cleaning bath in- dependent speeds from ft. per min. Manual field control determines the speed each motor changing coil speed, builds the drum, compensated for means variable voltage applied the gearmotor armature, and con- trolled rider rheostat acting the field its particular generation. This installation uses Westinghouse two hp., two hp., and two hp. units with reel drum in. diameter mounted directly each the slow-speed shafts. have capacities 2000, 4000, and coils respectively. a n n n s enamel drying oven for steel signs. The heater unit and control panel are shown near the middle. the left the cooling zone, which extends out from the furnace distance ft. OVEN REPLACES DRYING interesting oven installation operation the plant the Massillon Cleveland Akron Sign Co., Massillon, Ohio, for baking synthetic enamel coatings onto steel signs. The signs vary size wide ft. long, which makes the installation unusual, since this the first fully automatic unit devised for such large size signs. The entire system has been satisfactory oper- ation for six months. Prior the installation the auto- matic equipment, the signs were air dried large wooden racks which were trucked about means plat- form trucks. Depending weather conditions, the drying time ranged two days per coat. Sometimes multi-color sign job the time process has added days. The old method was not only slow but also cumbersome and costly. The new equipment, which was de- signed and installed the Morrison Engineering Corp., Cleveland, consists hydraulic elevator, panel type convec- tion heated recirculating oven, cooling zone, Tramrail system, power convey- ors, and control systems. throughout the various stages the system, large steel racks vided. One these racks shown emerging from the furnace, extreme left, the accompanying illustration. Each rack measures ft. in. wide ft. in. deep ft. in. high signs. Each rack will hold 120 smaller signs one The racks are equipped with two 4-wheel Cleve- land Tramrail trolleys. The oven proper ft. in. long ft. in. wide ft. in. high, and built 4-in. interlocking oven panels for walls, roof and floor. The entrance and exit openings for the work are the side the oven (see illustration), and are closed means automatic roll-type doors, synchronized with the operation the conveyors. the exit end the oven ft. in. long cooling zone provided bring the freshly baked signs room temperature. Cold air taken from the roof and passed through air filters into streamlined high pressure ducts, means high pressure blower. The loading elevator consists structural within which rides the elevator bridge. The bridge held position cables which turn are operated hy- draulic cylinder which operates auto- matically conjunction with loading conveyors. The oven proper equipped with double strand floor type pusher con- veyor intermittently operated, which engages the racks and propels them through the oven crosswise tion. The floor conveyor driven from motor through Reeves variable speed pulley unit double reduction worm gear reducer equipped with Mercury Torque limiting clutch. The clutch headshaft drive conven- tional drive chain. The Reeves unit gives flexibility travel within the oven and the Mercury clutch prevents jamming racks limiting the torque that value required start and move the load. Conveyor operation controlled variable sequence timer which di- rectly starts the floor conveyor pre- determined intervals. The movement the floor conveyor actuates the two runout conveyors which deliver the rack the cooling zone synchron- ized movements. The only manual step the operation the system the pushing the empty rack onto the elevator and the pushing the loaded rack into the oven. All other operations are done automatically, ex- cept unloading the racks. the exit end the racks are pro- pelled two synchronized overhead pullout conveyors which automatically transfer the rack from position the oven longitudinal position the cooling zone. The change position done through the use electrically operated Tram- rail switch gear. From this conveyor the racks are transferred another conveyor which delivers them the unloading zone, where the signs are manually unloaded and the racks are then delivered the loading elevator for the next cycle. The oven and system have capacity racks per hr., with baking cycles variable from min. hr. The temperature ranges from 200 deg. 350 deg. maximum. The fuel used low pressure natural gas. Morri- son direct gas-fired air heater with special large volume fan the prime heat source. The oven control cabinet. The features this cabinet are delayed purging, automatic igni- tion and automatic protection against fan, power, control, air gas failure. The control system for the oven and also interlocked automatic sequence control total 33% hp. elec- tric motors centrally located independent control board. The Massillon-Cleveland-Akron Sign Co. reports improved luster and finish each sign, which has increased the weathering life its signs for the same quantity paint heretofore used, THE IRON AGE, July 20, i & mite : OADING tray small parts into Hydryzing furnace. The quench tank below. heat treater intensely inter- ested process permitting loading parts into harden- ing furnace and bringing them out hard with their original faces. Particularly has this applied smaH production parts such springs, stampings, and the many varieties screw machine parts which are hardened resist wear Development the new Hydryzing for the Lind- -berg Engineering Co., 228 North Laflin Street, Chicago, makes available the smallest heat treating shop process claimed harden such parts absolutely bright with trace scale dis- virtually impossible distinguish appearance whether not the parts have actually been hardened. Origi- nally developed the plant the Lindberg Steel Treating Co. for the treatment tools and dies, the Hy- dryzing process was found provide 32—THE IRON AGE, July 20, 1939 work that nature that modified furnace has been designed which em- bodies features which would enable used for the bright hardening small work addition the regu- lar run tools, dies, and costlier type parts. Bright hardening small parts said have actually been found result considerable produc- tion savings, not even considering the very great improvement the appear- ance the finished work. The first saving claimed the amount handling which nated. Generally, when reasonably scale-free surface has been necessary one two different methods has been used. The parts were either pack- hardened, hardened from molten bath some type; both involve con- siderable handling order prepare the parts for hardening. the case the first method, the packing the parts some carbonaceous material BRIGH IARDENING SMALL PARTS such pitch-coke, charcoal, bone- black required, and this operation necessity carried out manu- ally. the case hardening molten bath, the parts must wired together that they can immersed the bath without tending float the top. Due dust and dirt, working conditions the case pack harden- ing are not all favorable, and the same holds true the molten salt method where the hardener must con- tend with heat and fumes well the ever-present hazards splattering due small quantities moisture the work. spite these disadvantages, much greater hazard present both methods, and that the difficulty maintaining neutral hardening that the parts are neither carburized nor decarburized, and particularly the for- mer. Even slight carbon pickup will result brittle part which has little resistance fatigue, and case, however slight, often renders the part useless because the result- ant brittleness. the Hydryzing ess all packing and wiring together parts eliminated because the work merely loaded onto the fur- nace hearth the normal Secondly, the Hydryzing atmosphere 3 said completely protect the parts against either pickup loss carbon that physical properties can con- sistently maintained Because the surface Hydryzed work bright and clean, pickling cleaning operations such sand- blasting are considered necessary. some types work, such gears heavier work where the unit costs run comparatively high, the elimination cleaning cost little importance. However, production items such springs and stampings, where the unit costs may run fractions pennies, the elimination cleaning sand- blasting, and the extra handling in- cidental those operations invariably results substantial savings because these expenses bear larger percent- age the total cost than they the case parts whose cost reck- oned dollars rather than pennies. also recognized that blasting pickling frequently produces minute pits the surfaces the parts which not only reduce the luster the finished work, but, the event that the parts are later plated, these small pits make more difficult secure smooth and shiny plating job. Considerable difficulty has always been experienced pack and salt-bath methods hardening light section springs thicknesses from 0.006 0.015 in., for example. Here, the parts are scaled during hardening the loss total cross-section may great weaken the spring dangerous point. The loss 0.001 in. due scaling during hardening not all uncommon, and such loss spring 0.006 0.010 in. thickness prohibitive. retaining the orig- inal surfaces intact, Hydryzing said make possible harden such work without the slightest danger. protective gas screen curtain introduced the front the fur- the chamber against the entrance the unwanted outside atmosphere. The gas for this curtain produced charcoal generator. This com- paratively simple unit consisting insulated cylinder, lined with firebrick which air, supplied small blower, passed through bed burning charcoal. additional, and most important, effective feature the very tight door sealing device which insures tight seating the door thereby preventing the entrance oxygen and also preventing the escape ILTING- HEARTH nace withquench. circulating the gases from the furnace cham- ber. Ordinary anhydrous ammonia, the same used refrigerating plants, introduced the rear the fur- nace chamber. The flow ammonia controlled small needle valve, and consumption low that tank lasts between and months, depending the size the furnace Accurate records kept number Hydryzing installations are said show average cost approximately 10c. per hr. operation for the protective gases. This figure, course, does not include energy for the heating elements the furnace chamber. pointed out the company that bright hardening can carried out shops having even the most limited production, standard fur- naces are available with chamber dimensions in. wide in. deep in. high and larger, and the fact that this type Hydryzing fur- nace not only takes care the bright hardening springs, stampings, and other small parts but also the harden- ing all types tools and dies, makes useful furnace for the aver- age hardening room. order secure perfectly bright surfaces hardening, necessary not only protect the work against scaling while being heated, but also while being quenched. take care the latter simple tilting hearth arrangement was developed so. that when the hearth tilted the parts drop through sealed chute the front the furnace chamber and down into the quench. The bottom the chute extends into the quenching medium and therefore sealed that air can enter and discolor the work. The hearth tilted means lever the side the furnace. When tools dies are being treated the hearth remains the horizontal position. addition the bright hardening steel parts the Hydryzing process said effectively used the annealing non-ferrous metals, par- ticularly copper. Recent installations for this type work include furnace the plant one the country’s largest gasket manufacturers, where considerable difficulty said have been experienced annealing copper washers dead soft condition. The Hydryzing unit brings the washers out with absolutely bright, true copper finish, and great deal expense has been eliminated the form tedious pickling operations remove seale. THE IRON AGE, July 20, 1939—33 URING the past few years there has been much talk about es- tablishing floor wages and ceiling hours workers indus- try. Concrete expression given this idea not only the national Wages and Hours Law and the minimum wage acts different states but hundreds union con- tracts. Minimum wages today are progres- sively being subjected ever increas- maxima, and maximum hours steadily decreasing minima, until the average worker than fair amount justification for feeling that wages and hours are more matter fiat than economic law. Under such circumstances may not amiss examine anew some the fundamental aspects the wages and hours problem. There undoubtedly floor wages and ceiling hours. But how about ceiling wages? And floor hours? Maximum wages and mini- mum hours are important consider- ations the proper solution indus- trial relations minimum wages and maximum hours but yet they have received very little study. Wage Scales Most wage scales union contracts are based upon either hourly rates piece rates. Straight time, the most commonly used plan, well the most simple plan, most readily applied un- standardized work, the product which per employee cannot easily metered. Under this plan the 34—THE IRON AGE, July 20, 1939 costs are high low production and low high production. Production per employee is, however, usually low. Unit costs are, therefore, generally high. Unit costs tend, moreover, increase during slack periods. Piece rates may almost simple time rates. They have the advantage over time rates that they afford constant unit cost production. They also offer greater incentive able workers since earnings, instead depending upon motion the clock, rest upon their own effort skill. Piece rates are particularly available for work steady, repetitive char- for independent tasks capable being performed in- SUCCESSFUL HERBERT SWAN dividual worker acting alone. some instances piece rates are supplemented with guarantees minimum time rate. Setting and maintaining manner fair both worker and em- ployer matter considerable dif- ficulty every industry. Seldom does either side analyze its problem scientific and businesslike fashion with reference what the industry can the basis past operating experience afford. The rates struck are usually rule-of-thumb rates representing not much something based upon the measured output merely the maxi- mum concession the negotiating com- 7 | “ | i \ \ \ \ \ \ < \ | \ \ A \ \ \ \ | WAGE POLICY CONSULTANT, NEW YORK mittee for labor could wring from the employer. Sometimes the piece rate schedule supplemented with extras which are set When new styles are introduced, not because their production requires special effort skill but because the higher price obtained for highly styled merchandise. later stage the style cycle, when the innovation has, effect, become standard merch- andise, the market quotations also become normal and the premium price heretofore commanded the product account novelty drop- ped. But the extra wage rate continues added cost burden production. Even where the introduction product may require added effort the part the worker initially, the extent the additional effort re- duced the product becomes more standard and production methods more refined. With the installation new machines improved type the rates may actually become obsolete. Rates evolved for present machines may wholly inapplicable improved machines and may, indeed, even im- pose obstacle the future use modern equipment, thus burdening the industry with obsolescent machinery. Extras for new styles sarily set the basis prior production experience. After the rate set refinements methods ma- labor saving de- vices are installed the basic industries that both labor and purchasing power may released for the manufacture and dis- tribution new goods for which there has pre- viously been either very limited mar- chines may result such increased production convert the extra into preferred rate, favoring the operators particular machines who may not more skilled than many fellow em- ployees. The effect such case set privileged group with higher earnings than those received other workers equal skill, responsibility and experience. Every wage rate scale set tends get out adjustment immediately after has been put into effect. These maladjustments need watched and eliminated insofar possible unnecessary burdens are not handicap either the workers the industry. the relative importance wages reduced; that overhead—interest, depreciation and obsolescence ma- chinery greatly increased. The greater the overhead content the per unit cost the product, the greater also the need for high pro- price. order meet this situation various bonus incentive plans have been worked out which have their object increasing output through re- warding the worker for performances above task where most production expected take place. Leaders organized labor, desiring workers feel more dependent upon union con- tracts than upon their own efforts securing increases pay, have quite generally opposed incentive Such plans are found, therefore, mostly unorganized shops. discussing wage rates may THE IRON AGE, July 20, 1939—35 f ~ j | > } 4 j j 3 = j j / fy / ( “> | only the common laborer emerges into skilled workman does obtain certain security against the more intense price competition always threatening the well remember that low hourly rates not necessarily indicate low labor costs. Nor need high piece rates pro- duce high earnings. Both may reflect low standards efficiency. Incom- petent labor usually, regardless its rate pay, high priced labor. employment, instead being asset industry, frequently the most formidable obstacle its successful conduct. The financial success plants low wage centers often due not much labor costs the use up-to-date machinery, better organization and superior manage- ment. Differentials Based Skill Adequate wage differentials based upon differences skill are essential requirement every satisfactory wage policy. Differentials, reflecting manner acceptable the average worker the varied requirements skill, training, responsibility and effort 36—THE IRON AGE, July 20, 1939 associated with different jobs ranging from common highly labor, constitute the strongest incen- tive the development skill for the higher standard living and increased social prestige which accom- panies larger pay envelope which prompt individual assume the necessary self-discipline incident becoming trained mechanic. the past, everybody concerned with industry, management than labor, well communities which workers live, has paid entirely too little attention the need for developing skill-man-power. Workers communities built upon the indus- trial exploitation unskilled labor, always competition with hordes unskilled workers both home and abroad, are usually paid but bare minimum subsistence wage. matter how low their wage, there are gen- erally some, hungrier for work than they are, willing work for less. The small buying power possessed such labor confined the basic necessities life leaves small margin for the purchase those comforts which measure the cultural advancement community. Only the common laborer emerges into skilled workman does obtain certain security against the more intense price competition always threatening the wage level the un- skilled masses. Common labor, being interchangeable with little spe- cial training, available all indus- try. Every laborer is, therefore, greater less degree, competitive with every other unskilled workman. But this not with the trained tive with other mechanics within his own group, not interchangeable with mechanics outside cular group. lathe operator not available for the job lithographer cabinet maker ineligible for the job textile printer. only through the development special skill that each individual worker can protect himself, his job and his wage from the keen competition surrounding the employment common labor. The wage differentials essential the development and maintenance this skill are today being impaired, feared, the negotiation many union contracts which, through the adoption either flat increases much per hour per week in- verted scales graduated increases, have the effect narrowing differ- ences pay skilled and unskilled workers. This particularly true industries which skilled workers are small minority. There the shop committees appointed for collective bargaining have sometimes been more interested satisfying the increased wage demands the majority un- skilled workers than maintaining wage differentials requisite perpetu- ating the group highly skilled workers the industry. some in- stances wage differentials have been whittled down point where they are insufficient retain the superior ability man the industry. Rigid Work Week With work week flexible increased production may reflected, not through increases the number employees, but through lengthen- ing the work week. But with hr., increased production must, once those present payrolls are employed full time, accompanied with cor- responding increase the number 4 employees. For full time new perma- nent employees, this should be. But rigid union contractual regulations rigidly enforced insist upon this prin- ciple being observed even the case industries subject sharp seasonal fluctuations where limited amount overtime the part regular em- ployees for short periods would make ample provision for temporary produc- tion requirements. Management, for- bidden work regular employees over- time, must hire new workers requiring considerable training increased supervision. such cases the man hours per unit product often shoot upward with increased production, showing that the which should obtained with ex- panded operations has been offset the less efficient effort new workers. The principle fixed work week may rigidly applied pro- duce utterly impractical situation within industry both manage- ment and labor. Unless some mea- sure administrative flexibility provided make necessary adjust- ments for above-standard standard employment cycles the way elastic week, the industry forced into multiple shifts the em- ployment extra help which may time become invested with certain permanent rights stand-by help. The serves many instances accentuate fluctuations the employment regular employees, taking work which rightfully belongs them and giving half-starved unnecessary super- numeraries the fringe the in- dustry. Plant Modernization worker’s productivity can seldom considered separate and apart from other factors contributing produc- tion industry. Since productivity” fact productivity the whole industry averaged over the number employees, the ability the employee often secondary gen- eral conditions under which works determining production. Character tools, capacity machines, quality materials, adaptability buildings, effectiveness management and such considerations are often quite portant the worker’s own compe- tence controlling the output per Wages are generally highest where capital per employee utilized great- volume. The installation modern machinery, reducing unit costs and thereby promoting increased Production, constitutes Prerequisite the payment satis- wages. the retention obsolete machinery imposes heavy drain upon wages, labor should the first recognize the need for har- monizing wage policies with the re- quirements for modernizing plant and equipment. And yet limitations upon work loads detailed standards and extras regulating wage scales found union contracts are among the most obstinate hindrances the modernization different indus- tries needing new machinery. Occasionally union rules oblige em- ployers stagger displaced help re- sulting from the introduction labor saving devices. The consequence that the economies which program modernization would effect are held abeyance since new machinery, which would otherwise installed, not purchased. such instances, em- ployers are inclined take the view that there use buying machines which would displace men when they would still have provide full time employment for the displaced help. Wages, being paid out the work- own productivity, can raised permanently only through increased production the part labor; in- creases hourly rates can main- tained solely through increased output. Unreasonable work undue interference with management securing effective use labor, soldiering the part the worker- all are disastrous efficient and eco- nomic production, and therefore payment satisfactory wages. The fatal idea that restriction output in- creases wages dies hard. Labor Saving Devices The introduction labor saving devices the basic industries has had and still having most profound effect upon the whole industrial struc- ture; for only such devices are installed that both labor and purchas- ing power are released for the manu- facture and distribution new goods for which there has previously been either very limited market. the price the products made the particular industry introducing the labor saving device reduced, may result the development much larger market for its products that both the labor and purchasing power released the new invention process may absorbed within the industry itself. But the market the industry utilizing the new device may unable absorb such increased volume goods. that event the displaced workers will available for employment new industries and the wages heretofore paid them released for the purchase new merchandise. Axiomatically, labor saving devices will not installed unless their use accompanied with sufficient reduc- tion labor costs justify installa- tion. Their introduction must, there- fore, the long run reflected displacement labor. Should technological change re- Hect itself such abbreviated work week retain present employees the industry, its benefits will spent affording workers increased leisure. Over the years, the work week has been reduced from and hr. its present length from hr. through partial absorption these benefits. all successful indus- tries the shortening the work week has always followed, never preceded, technological advance. other words, the productive efficiency the indus- try has outstripped the r