The Iron Age 1939-08-24: Vol 144 Iss 8

WRIGHT Managing Editor Machinery Editor OLIVER CAMPBELL FRITZ FRANK President J. H. VAN DEVENTER Editor ROWAN News Editor Art Editor Associate Editors PHAIR Washington Editor Resident District Editors RoBert BINGHAM Pittsburgh Chicago JAMES Cleveland Detroit London, England G. FRAZAR Editorial Correspondents Cincinnati Boston Hamburg, Germany Milwaukee San Francisco SANDERSON Toronto, Ontario Leroy ALLISON Newark, N. J. Publication Office Chestnut and Philadelphia, Pa. Birmingham St. Louis JR. Buffalo Owned and Published CHILTON COMPANY (Incorporated) SHERMAN A. 1, FINDLEY Editor Emeritus Metallurgical Ediior RICCIARDI ASA ROUNTREE, JR. toy Editorial and 56th Sts., 239 West 39th New York, N. OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, Vice-President Vice-President Vice-President Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE, THOMAS KANE, CHARLES BAUR, BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Emerson Findley, 621 Union Bidg., Member Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ADVERTISING STAFF B. L. Herman, Chilton Bidg., Phila. H. K. H. E. Hottenstein, 1012 Otis Bidg.. Chicago Leonard, 239 W. 39th St.. New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York Ww. W. D.. Don F. Beach, Cal. 428 Park Bidg., Pitts. Warren, P. 0. Box 81. Hartford, Conn. Harner, 1595 Pacifie Avenue, Long Cleveland Executive Offices St. Contents AUGUST 24, 1939 Floods the Subway, Inclusions Rimming Steel Metal Spinning Comes Age What's Your Job Stampings Build New Business Weirton Opens Structural Mill Mud Gun Redesigned Welding Galvanized Sheets Carbon Arc Car-A-Minute Car Dumper Statistics Metal-Working Activity Washington News Weekly Ingot Operating Rates Rate Activity Capital Goods Plant Expansion and Equipment Buying New Industrial Literature Just Between Two Products Advertised Index Advertisers Copyright 1939 Chilton Company ia H ul, nal | us, ind and nal onal d. | 122 COST per Steel Rolled with NIX are engaged solely and future “ the kind rok only specialization can that account any and all conditions, PHOENIX ROLLS PRODUCTION SCH AND LOWER COSTS IN... Strip Mills Blooming Mills Slabbi Mills Plate Rail Mills Sheet Tin Mills Red Mills Skelp Mills Merchant Bar Billet Mills Pipe Tube Mills PITTSBURGH Division Blaw-Kne PITTSBURGH, Est | | | | q q q | q AUGUST 24, 1939 Established Vol. 144, No. Floods the Subway, Etc. this written, the morning paper tells cloudburst the County Queens, Y., that halted the Independent Subway System for nine hours. very un- usual occurrence. Hundreds passengers had get off and crawl along catwalks the nearest station. What cussing these people probably gave the subway company, its builders, its engineers, its equipment, and its operators! This one failure complex and highly mechanized system the worst caused more than slight inconvenience limited number people. And these same people, day after day, week after week, and month after month had enjoyed the long- est, fastest and smoothest train ride the United States the lowest cost per mile, without ever giving thought thanks the technical achievements that made possible. Most people accept without thought thanks the benefits that they receive daily from technical progress. But let there the slightest interruption cause tem- porary inconvenience and the benefits are quickly forgotten. machinery quiet and unspectacular. does not advertise itself the public. The clang, the Anvil Chorus associated with hand work, not with mechanization. Because its modest, unspectacular working methods the improved machine has been susceptible misinterpretation, particularly the lay public. And the more remote from the daily lives laymen the machine happens be, the more liable misunderstood deliberately misinterpreted. John Public does not appre- ciate the day and day out service the mechanized modern subway, how much less does realize his economic relation lathes and continuous mills and broaching machines that has never seen heard of? And John Public, who would kick someone proposed raise the cost subway transportation decreasing its technical efficiency, does not realize that the legislative restrictions proposed for the use these less familiar mechanisms would penalize him increasing the cost everything that buys. That why The Age undertook its present campaign for the improved machine. Our problem, industrial publishers, was the rather unique reaching people who not read The Iron Age. And now, the two-thirds mark the campaign, are ready report progress. Through newspaper reprint- from coast coast, house organs and other media, The story personal relation the machine John Public has already been carried over million American laymen. has been big job; but, judging industry and public reaction, well worth the time and effort. q | ¥ | q F ry } i i 4 Are fore ; ni ilis & The cars that fill today’s highways are sturdier, safer, more beautiful because they’re built steel. And here, particularly, American leader- ship engineering and manufacturing sets the pace for the rest the world. For years, Inland metallurgists have ated with American motor car builders pro- ducing cold rolled sheets suited their specific requirements for deep drawing, and for fine finish Doors the Open are made INLAND and other qualities. That why, beneath the sleek lines many the best-known automobiles, found the sheets that come from Inland’s mills serving many other industries well, Inland staff constantly the alert better steels suit each manufacturing method. wise, from time time, discuss your quirements with Inland Steel men. request from you involves obligation. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING cl 4 A steel widely used for deep-drawing purposes, and, since the in- clusions contains have such direct influence draw- ing properties, any study re- lating inclusions perform- ance great value. this, the first section two-part article, the authors cates, between sulphide banding and inclu- sions, occurrence silicate inclusions, etc. trend for the past few years has been steadily toward sub- stituting deep drawing for ma- chining operations wherever possible. this practice has become more and more universal, fabricators have found ° Metallurgical Department, Republic Steel Corp., Warren, Ohio increasingly important have steel available which possesses uniformity from the first the last piece put between the dies. Steel makers, meet such exacting requirements, have had the alert not only maintain existing high standards quality, but also im- prove the product wherever and when- ever possible. secure high-quality deep-draw- ing steel involves number factors, including surface and physical proper- ties, well rolling and heat treat- ment. The type steel which has been found most likely have these properties, all them important, made the rimming process. Because rimming steel widely used for drawing purposes, and be- cause the inclusions contains have such direct influence its proper- ties, has been found very much worth while study the inclusions and observe their relation actual per- formance strip and sheet products. The types inclusions found rimming steel fall into two general classifications Sulphides and silicates. These types differ not only com- position, but also location. The sulphides segregate principally the upper portion the ingot, while the silicates are found mainly the bottom. The-general consensus in- vestigators has been that sulphide in- clusions are detrimental all types steel. However, the results in- vestigations the authors would in- dicate that this effect confined rimming steel only and due the fashion which the metal solidifies. Sulphides Included sulphur not only takes the form manganese sulphide inclusions, Fis. between sulphide banding and inclusions. (Left) Etched electrolytically, showing segregated area. (Center) Etched with copper reagent, showing the presence bandings. (Right) Unetched, showing distribution sulphide inclusions. THE IRON AGE, August 24, 1939—23 4 - > \ > ie t \ . q “by duce | | | Curve based abundance manganese sulphide inclusions Position ingot, per cent but also exists soluble segregate, which appears the form banding ghost lines the rolled product. The intensity this banding dependent upon the degree deoxidation. thoroughly killed steel eliminated, and semi-killed steel its intensity relatively low, evident, therefore, that oxygen steel has important bearing upon banding soluble segre- gates. rule rimming steel, the in- tensity banding pretty good in- dication the extent sulphur segre- gation the ingot. fact, the rela- tionship between these sulphide phases close that neither can con- sidered separately. This seen Fig. which this relationship between sulphide banding and sions quite evident. has previously been stated, the degree segregation the included Position ingot, per cent 24—THE IRON AGE, August 24, 1939 BOTTOM ° These data demonstrate that the change physical properties from the top the bottom the ingot persists through the cold rolled and an- state well for plain hot rolled steel. BOTTOM sulphides greatest the upper por. tion the ingot. Progressing toward the bottom (see Fig. 2), there gradual decrease the intensity segregation, and the bottom third the ingot the condition has practically disappeared. illustrate this, the chart shown Fig. has been prepared, based systematic study rimmed ingots, representing different heats. Tests ° ° ° Amount clusions position ingot. TOP INGOT Cold strip, average Olsen and Rockwell Rockwell values Position ingot, per cent BOTTOM Olsen values Olsen values Per cent were taken from predetermined loca- tions, each one representing partict- lar section ingot. The terms “heavy,” “medium,” “none,” have been adopted indicate degrees segregation, and the micro- graphs shown Fig. were taken standards for comparison. The top portion the ingot represented the chart reality the top after cent discard was made. The ages specify the portion (from the extreme top) which the tests were taken. per cent from the ingot top ° Banding relation position ° ° ° ° ° coils standard test | ° ° ° / | | | per cent the tests displayed demonstrates that the change phy- the end columnar crystalliza- banding, per cent “medium sical properties from the top the tion, dendritic solidification begins. banding. per cent from the top bottom the ingot persists through Since this solidfication also starts with dof (roughly from the middle the ingot the cold rolled and annealed state the purer portion the metal, the re- the “heavy” banding came down well for plain hot rolled. maining liquid gradually increases per cent, “medium” remained about This concentration impurities, the per cent, and “light” banding in- same time moving upward and toward thirds from the top, the banding was the dark areas, along the inner line vanished altogether. was region where the blow holes, which are angle also found that the distribution and holes exist the purest portion the the central axis, show this entrapping amount manganese sulphide inclu- and its chemical analysis al- impurities due the increased vis- sions followed very closely the line ways shows lower percentage cosity the metal with falling tem- “heavy” banding. impurities than the ladle analysis, perature. This process continues un- it oca- rms and quite obvious from the fore- which the average analysis the til the last bit solidify, highest going that gradual change physi- heat. undoubtedly because that impurities, the top central por- should accompany the portion the liquid which solidifies tion the ingot; Fig. the dark similar change concentration and first has the highest melting point, and area directly under the pipe cavity. the types impurities. This change consequently purest. Its solidifica- the greater hardness and lower tion increases the concentration im- Silicates ent- ductility the upper portion the purities the remaining melt, par- Silicate inclusions, general rule, the ingot the lower hardness and greater ticularly just before the growing crys- refer silicates occurring killed ductility the bottom portion. Fig. tals. During this period rimming action steels containing chart which direct derivation going on, and goodly portion and relative amounts How- top the following through processing the coalesced impurities have been ever, rimming steel, silicates, con- ten ingots the same mechanically removed. sisting mainly iron and manganese standards are used indicate the degrees gation. ° Pray set erty x ae THE IRON AGE, August 24, H Pee { 3 | q 4 a i” a 6—Sulphur print section through the central axis 22x24-in. ingot. IRON AGE, August 24, 1939 # rolled strip, indicated above arrow. close-up view .of this same pipe shown the 9—(Left) Blister inclusion hot-rolled strip. (Right) Same type after cold rolling. Note the breaking the inclusion. Both steels unetched and viewed 100 diameters. = 7—Skin pipe plain hot plain hot-rolled strip. Actual size. * sion and oxide with, relatively, small amount SiO, and are also present. Strictly speaking, may more ap- propriate call them iron-manganese- aluminum silicates. The practical sig- nificance this type inclusion deep drawing rimmed steel trated the examples failure commonly known skin pipe small lamination shown Figs. 10. rule they not possess com- structure, but are present the form fusible glass. Such inclusions generally exist thin films the rolled product, indicating plasticity the strip mill temperature. Under the reflecting microscope, these inclusions exhibit monotone color gray, and the difference composition between one particle and another clearly discernible. However, inclusions are extracted, and examined under the petrographic microscope altogether different appearance noted. general, all are transparent, but there great deal difference the comparative transparency individual particles. The color these inclusions also varies within surprisingly wide range, varying from frosty white, through light yellow, pink and dark brown, light green intermingled with opaque particles. The occurrence silicate inclusions was studied three different ways: (1) microscopic examination ingot sections, using the micro-count method determining the relative amount inclusions present; (2) microscopic examination large number hot-rolled strips which the position the ingot was known; and (3) blister tests which small inclusions near the surface are dis- closed the form blisters under severe pickling operations. sions was studied micro-count section taken in. deep and point about per cent from the bottom the ingot. shown Fig. 11, the size and number inclu- sions within the first in. from the surface are relatively small. abrupt drop noted the next in., then sharp increase both number and size the fourth and fifth inches from the surface, after which there gradual decrease. other words, the highest concentration inclusions between and in. from the sur- face the ingot. The columnar blow holes are just previous the concen- tration, and this high concentration tremely thin layer blister inclusion, unetched and 500 diameters. left) Blister inclusion the type most frequently found close the central axis the strip. ° ° inclusions corresponds the inner line blow holes which is, roughly, about per cent the entire thickness the ingot. All the inclu- sions found the ingot were spheri- cal shape, and under graphic microscope found forms glass. Micrographs the extracted inclusions are shown Fig. 12. The ingots followed the study banding and sulphide inclusions were also utilized the study silicates the second method. Samples from the known portions the ingot were examined microscopically the number and size silicate inclusions each were compared. This micro- count entirely relative and because 12—(Left) Semi-glassy type inclusion, extracted from the ladle tests; diameters. Opaque type inclusion, ex- tracted from the ladle tests; diameters. (Right) Opaque inclusions, extracted from the ingot; diameters. THE IRON AGE, August 24, 1939—27 | Distribution inclusions inan ingot from surface interior represented interior represented per cent number test Involving with 36.5% blisters Position ingot, per cent 28—THE IRON AGE, August 24, 1939 BOTTOM ° ° ° silicate inclusions sec- tion taken in. deep and point about per cent from the bottom the ingot. ° ° 1G. Amount blister and pipe forming inclu- sions, relation position got. the variation the number and size inclusions from ingot ingot, and heat heat, the actual figures cannot apply any other single The most frequent occurrence cates was the bottom portion the ingot, and the majority them were located surface the center the strip, ing very closely the zone inner line blow holes the ingot. addition, such inclusions were also found the middle the strip the central axis the ingot. However, they were fewer number and the amounts did not in- crease sharply the bottom the ingot was approached. The third method, severe pickling strip samples from known locations the original ingot, substantiated the results obtained the two foregoing investigations. The results this pickle test were accumulated over period two years and involved 4400 tests representing known positions 880 ingots. The data from these tests are plotted Fig. 13. The graph closely resembles the one obtained microscopic examination. About 3000 these blisters were opened deter- mine the condition variably inclusions were found, which the majority cases were brown- ish gray color, and luster. The large number blister tests from known cuts the ingots were made determine how regular the curve from microscopic examina- tion really was. The existed consistently and can taken general rule. This test also vealed that the amounts blisters the heats are relatively uniform. That is, the ingots representing the first, middle, and final portion the heat produce approximately amount cleanliness. Excluded from consideration, course, are the last few ingots poured, since these often are accompanied the slag the pouring. The ingots used the those used the blister tests, had their tops cropped off roughly pet cent. Therefore, while would appear indicate the top being most free from blister forming inclusions actually this not the That particular portion does not show uniform results from ingot the same heat. Oftentimes quite free from blister-forming sions; then again the inclusions maj very abundant. appears that the cleanliness the top per cent Coo & £20 ome fi 0 t : * 40 ests aph 000 ter- In- wn- vere ular ina- first, heat last had per sults ming show ingot may the the ingot depends entirely upon the mechanical entraption the non- chemical reaction. Six ingots with very small top dis- cards were divided into cuts each and tested the same manner the 880 other ingots. Inasmuch the portions into which the ingot were divided were much smaller than the others, the derived data are not in- cluded the above, but instead are presented separately Fig. cording this, zone the middle the ingot has the least amount blister forming inclusions. these ingots had been divided into five sec- tions, the data obtained would have followed closely that the 880 ingots. Ed. Note:—Next week the authors will discuss the source inclusions and the mechanism inclusion formation. ° position got autobody sheets portion displaying skin blis- ters after test. Position ingot, per cent Rate Oxidation Steels per colors,” appear metals when the thickness the oxide film bears certain relationship the wave length the incident light. use interference colors, therefore, rela- tive thicknesses oxide films can compared. this means, Mc- Adam, Jr. and Geil have studied the influence temperature and film thickness the rates oxidation various steels. the July Journal Research, National Bureau Standards, Wash- ington, the relationship between tem- perature, time, and film thickness, for each steel, has been represented one more views three-dimensional diagram. means these diagrams, been shown that the rate oxi- dation varies high power (25 60) the absolute temperature. The tate oxidation, constant tempera- ture, decreases with increase film thickness, If, over short intervals, the oxidation time assumed vary the thickness, the exponent decreases with increase film thick- from 100 more about For constant oxidation time, the thick- increases rapidly with the abso- lute temperature. If, over tervals, the thickness assumed vary power the absolute tem- perature, the exponent increases with increase film thickness, from less about 25. The accelerating influence temperature the rate oxidation thus predominates over the retarding effect increasing thickness the film. means the three-dimensional diagrams, comparison made between steels various compositions, and discussion given the influence alloying elements resistance oxi- dation elevated temperatures. The rate oxidation depends the rate diffusion oxygen inward and the rate diffusion metal out- ward, through the oxide film. The rate diffusion oxygen, therefore, proportional the range oxygen concentration and the specific dif- fusional conductivity the oxide. The steepness the gradient oxygen concentration decreases with increase film thickness, but the instantaneous rate oxidation not inversely pro- portional this thickness. The de- crease the rate oxidation with in- crease film thickness too great accordance with the view that the range concentration oxygen and the specific diffusional conductivity are invariant with film thickness. the range oxygen concentration the specific diffusional conductivity, both, must greater for thin than for thick films. film rubber applied the form latex sometimes used means protecting the polished surfaces metallic mirrors and similar articles from scratches and dust while stor- age and during shipment. When ordi- nary commercial latex applied polished aluminum, however, bluish discoloration produced which re- mains when the film rubber stripped off, according recent re- port the National Bureau Stand- Tests which were made ascertain the cause this discoloration indi- cated that was produced, not the rubber, but ammonia which al- most universally employed pre- servative for latex. When the am- monia removed dialysis through cellophane membrane, latex longer discolors aluminum. Ammonia-free latex preserved the addition the requisite amount pure formaldehyde likewise without action aluminum. THE IRON AGE, August 24, | ind res the the ing < the ing this 400 | = recent years number engi- neers have recognized the fact that metal spinning has great potential usefulness industry IF: (1) its range could widened include ferrous metals; (2) its scope could expanded order form intricate shapes hard modern alloys; (3) and this work would measure exacting industrial standards precision. Ed. Note:—The author general manager the Milwaukee Metal Spinning Co., out- standing exponent this technique forming metal and originator many the important advances recently made this relatively known and certainly little understood branch the metal working industry. Mr. Salow has stated willingness handle direct corres- pondence any questions readers may wish have answered. 30—THE IRON AGE, August 24, 1939 has long been known that sub- stantial savings production costs often might gained and many instances distinctly superior product formed, the three important ob- jectives just mentioned were realized. certain plants the art spin- ning has been developed meet the three objectives mentioned, and the process being exploited rapidly list industries, which have become conscious the advantages provided this technique forming metal. Really complex spinnings practically all metals are now being used aircraft, automo- biles, machines and tools, orna- metal works, and long list THEODORE SALOW, Jr.* ° ° ° manufacturers food processing equipment and builders goods equipment. For industrial purposes there been three standard methods ing sheet metal. large volume production, stamping has been and still the most economical means mechanically forming seamless shapes. Possible some work, but seldom used, the old smithy method ing the gap between the latter one- at-a-time means production and the former 100,000-at-a-time metal spinning—a process form- ing metal that provides for the pro- duction articles small lots nominal costs. simple spinning may turned out skilled craftsman few minutes time. The machine used lathe, somewhat similar wood- turning faster and more powerful. The first operation turn wood metal block the exact size and shape the object produced. Such block serves the same purpose spinning that die does stamping. The block can used make thousands and the original cost very small compared the cost die. The block screwed the spindle the spinning lathe. round, flat metal blank clamped against block, The lathe then started, ing both the block and the blank — q | 3 | | | i — Now, many formed metal articles may low cost, and with superior finished characteristics. This article gives the why, the what, and the how. The spinner selects tool, usually long, blunt steel rod, the blunt end which presses against the whirl- ing blank. expertly working the tool back and forth from the center the outer edge the blank, finally lays the metal down that fits over the block like glove. The spinning taken off the block, another blank clamped on, and the spinner again. Simple articles require but one operation; intricate article, however, may take several operations and anneals before finally spun the correct shape. The various steps involved spin- ning simple shape Figs. Spinners Are Artisans Perhaps the most important single factor spinning the individual skill the The variation pressure form desired shapes, obtain correct thicknesses -of metal, and avoid “work-hardening” ator has for his work. This “spinning temperament” requires artisan the full orthodox conception the word. Like every other measurement professional ability, the human shop largely determines capacity for work. also are the forms the tools used and the technique followed applying them. The operators modern spinning lathes use many the common tools, but the past few years great expansion types work handled has required the devel- opment wholly new kit gadgets, particularly those for working ferrous metals. These tools have been custom designed bring about certain desired results and reactions metal and are that are very closely guarded. business where indivi- dual skill and “knowing are the vital elements success, progress and betterment methods are kept “under wraps” for the same reason that com- petitive business and industry strive obtain copyrights and patents sonal corporate achievements. Limitations Removed Until few years ago, spinning was confined wholly non-ferrous metals such aluminum, copper, pewter, zinc, brass, and the shapes formed were limited very simple designs. From this stage, where spin- ning had been almost relegated recreational project for home work- shop enthusiasts, group indepen- minds refused accept final the established boundaries and began pioneer wholly new fields. Experi- ments were launched working sizes heretofore considered impractical for the lathe. Investigations were started determine the whole long list so-called unworkable metals really could not spun. All the hurdles were one-by-one successfully cleared. Characteristically, much this “spirit inquiry” was depression born, spurred the necessity finding new markets turn idle wheels. The first experiments were directed toward increasing the gage non- ferrous metals handled. Only few years ago, for example, the ability spin copper 1/16 in. thickness was considered remarkable. handle copper heavier gage made neces- sary find methods that would, the language spinning, “bring the metal down hurry,” that its ductile qualities would not change un- der the heat forming. this, new tools had developed, new spinning speeds determined, etc. To- day, these answers are known—and now copper in. thickness can spun without difficulty. new tools were developed for increasingly heavy gages ferrous metals, they were applied— with adaptations—to modern ferrous alloys that had previously been wholly beyond the ability the spinning lathe. Results were highly gratifying. metal after metal was introduced the spinning lathe, the industrial application the spinning technique broadened constantly. The greatest victory all, however, came when stainless steel was for the first time spun successfully. Spinning Stainless Steel Despite the fact that stainless steel theoretically ductile metal, had THE IRON AGE, August 24, 4 sing ume and sof nore the the die ngs, mall ndle flat the always shown discouraging tendeney work harden rapidly the spin- ning lathe. Long after the stamping industry had developed methods form the metal into various deep shapes, the spinner still found impossible metal handle. after years endless experiment cop- commercially feasible form few simple shapes. Since that time, ad. have been extremely rapid, and made possible the working really all complicated forms. spinning lathe with maple pattern (block) attached spindle. Just how fast and how far spinning judged the fact that only months ago the spinning flanged and dished head was regarded with open- mouthed wonder. Today, not diameter ball out gage steel. wa Valuable contributions the tech- nique stainless spinning were made number the leading producing mills. Characteristically, these com- panies made available for this search the facilities their laboratory resources and the personal time metallurgical technicians. Many cial melts were made test improve the ductility the metal, and the resulting improvement steel this work—has been important tor the rapid progress recently made 2—Operator prepares spin aluminum blank clamped against shapes. block, both revolving 2600 r.p.m. Much Larger Sizes spinning advanced into this new field ferrous metals and alloys, was matched corresponding gress handling sheer physical size spinning in. diameter was ago. Today spinnings large in. diameter are regularly being against metal and assumes shape block. Fig. (At pre- pares outer edge for trimming. | i tion made ficult new pro- size. was years being formed, and the trade believes that the maximum size has not yet been attained. Right now spinning the throes its own “industrial revolution.” Accomplishments that only year ago the sensational have al- ready become daily commonplace. Items considered impossible make even few months ago are being regu- larly produced today. short, indus- try whole must regard spinning field forming metal that lacks all finality its boundaries. Some the commercial applications these newly discovered methods are extremely interesting. The experience paper cup manufacturer provides illustration that has been frequently duplicated. This particular quired stainless steel mandrels for the production the cups. The company was accustomed purchase stainless castings which were then machined specifications—a process that was both expensive and wasteful mate- Spinning was investigated and samples produced for testing, and these spun mandrels were extremely satisfactory, being very strong and And not the least this manufacturer’s satisfaction with spun mandrels was the fact that they were produced cost per cent less than those made the old machining method. Aircraft Use Developing Another interesting application can found the produc- tion stainless steel engine cowls aircraft maker—a forming oper- ation requiring fairly large piece metal contrast the very small the paper cup mandrel. The company wanted fire wall housing made heat-resisting alloy, and tests indicated that stainless steel 5—Operator beads. Notice bead smooth, well rounded and clean cut. accuracy. Fig. (At com- pleted cover, which requires practically polishing. ning Fic. 6—Complete spinning removed. would best meet the requirements. However, the cost producing stainless 36-in. diameter cowl was en- tirely out relation its proportion- ate importance plane part. Fin- ally, spinning was suggested, tried, and found wholly successful not only forming structurally strong cowl- ing, but bringing the forming cost down common sense levels. Stainless Spinnings Help Food Industries One the largest consumers stainless tonnage the food and beverage industry and related sup- pliers processing machinery and equipment. The adaptability stain- less for this particular market too well known require explanatory comment, but the contributions spinnings the betterment program equipment manufacturers worthy interest. this field the production many vessels for holding liquid and semi- solid foods does not warrant the costs dies. This true both the largest manufacturers well the smaller. Containers were produced welding until spinning showed its ability producing bowls and tanks. Spinning produced that were very satisfactory every respect, and again, many cases where spinning has been applied, product improvement has been made more realistic lowered cost production. The initial application stainless spinning the food industry was the forming covers for filling and capping machines used dairies the bottling milk. (See Fig. 9.) Prior the introduction stainless, these covers were traditionally made copper and then chromium plated. Subject continually hard daily use, the chromium finish would wear away. This necessitated frequent replating costs, reserve covers, and other extras that added the cost operating dairy. Sanitary Standards Raised The use stainless covers, course, removed the curse re-plating and created attractive appearance that would all times impress visitors the sanitary standards the dairy. Even more pleasant, however, the fact that these better spun stainless covers are lower cost. Recently, spinnings have had the opportunity team with brilliant 34—THE IRON AGE, August 24, 1939 engineering advancement the dairy industry, the result being new piece equipment. few years ago machine was introduced injected vitamin content into milk, distinct sales asset. Milk thus treated was known then and still identified small dairies could not afford the very large capital investment required IG. diesel engine injector sleeve spun copper 0.109 thick— tolerances are extremely close. the machine. year ago an- other machine was perfected, that operated successfully and could sold prices within the means even small dairies. However, this machine was generally condemned sanitary authorities. because certain essential parts were produced method double seaming, soldering, and welding. Spinnings were suggested solution the problem fabri- cation that would pass all health de- partment requirements. The machine now being made with spun parts. Spinnings are important the and beverage industries for the greater strength seamless construction over general sheet metal fabrication Also, smooth, highly polished seamless construction makes absolute washing attainable, and leaves opportunity for cracked rough faces harbor refugee bacteria. Health authorities everywhere have gage and stainless and recommended the seamless bowl, Metal spinnings, being nominal cost and because the ranges metals weights, and forms are broad, cam mental and laboratory work. cylindrical shape—even whole —can formed spinning. sign parts changes are under form now helping sell all the making test models the ning process less costly. Many | 3 IS. 9—A 4 A tank orab Ottle foot Teater sur- Health the stamping companies have now turned spinnings form sample models for customer approval before expen- sive final dies are undertaken. Many good ideas product im- provement have been prematurely con- signed the grave because prohibitive forming costs have outweighed the gains. Spinning may afford practical answer many miniature scale model beer barrel that exact copy the fin- ished product. these engineering headaches. this method, almost any metal can formed cost that line with limited experimental funds. Exacting Specifications Met Many industrial engineers have the impression that when spinning em- ployed the method spinning metal, degree latitude must expected the finished product. generally believed that spinnings serve certain but when exacting specifications must held, spinnings can not depended for accuracy. spinning has “raised its include practically all metals and found itself able work increasingly larger sizes, also has parallel prog- ress been made toward controlling the accuracy finished work. modern spinning plant now can hold metal almost any set specifications, the way down micrometer measure- Take for instance the diesel engine, which extremely accurate piece mechanism. One diesel manufac- turer recently needed just few in- jector sleeves for special motor. checking various methods produc- ing these essential parts, was dis- covered that the cost ran into hundreds dollars. However, investigating spinnings was found that prices were well within the budget. Spin- ning produced the sleeves successfully (see Fig. 10)—made them copper 0.109 in. thick with extremely close tolerances. Considerable money was saved, and this particular manufac- turer has turned spinnings for the forming special parts. Scale Models For Salesmen From time time spinning has helped salesmen the heat” secure business that might otherwise have been placed elsewhere. Where products are bulky, heavy, and awk- ward carry, spinning made scale and faithfully reproducing every characteristic the product can employed help prospects visualize the actual article. the time prohibition was repealed and beer legalized, steel products manufacturer visualized large beer barrel market. This com- pany had never made barrels, but had the facilities. Tooling for pro- duction would involve $10,000 ex- penditure, and after that there was assurance that brewers would approve the product when once made. An- other deterring element was the es- sence time, the fact that the big bulk the barrel orders would placed breweries before the first barrels could produced for even demonstration purposes. From blue print the proposed barrel spinner produced miniature scale model (see Fig. 10) that was exact replica, characteristic and metal, what the finished barrel would like. (See accompanying these barrels were the hands the factory sales force. Instead hazardous spending $10,000 hunch guess, this steel products plant obligated itself pay for only spinnings, the cost being $212.00. Ornamental Architecture The modern trend architectural design frequently calls for the use rounded shapes interior exterior design. Stainless metals are being in- creasingly exploited, and rather likely that this trend will grow in- creasingly important. Already spin- nings have been employed some architects and contractors supply the cylindrical and spherical forms created the draftsman’s pencil. the knowledge spinning eco- nomical source for this type work realized and appreciated, designers will probably make liberal use this forming technique. THE IRON AGE, August 24, 1939—35 ° ° ° > achine spun ‘ vessel ninal can and EGARDING the method pre- sentation and the application point rating plan the actual grading job, all such plans seem fall into three general types: From Lists Key Joss: The first type consisted selecting few factors, normally about five six, and about key jobs which are ranked under each the factors selected. scale points may given each these lists, varying either cents per hour some other arbitrary set values, which aid lo- cating new job relation the key jobs under each factor. may seen, this method consists merely comparing one job with standard set jobs under each factor and add- ing the total points. The General Electric plan published Mr. Weed, the plan published Bass, and plan known the Job Fac- tor Comparison Method published Benge, are good examples this type. These plans are far supe- rior simply ranking without consid- ering the factors, for they approach the method fundamental analysis, and provide point scales for locating particular job some definite loca- tion the list. They lack descriptive definitions, however, aid locating point rating the job. RATING FROM DEFINITIONS AND SCRIPTIONS: The second type includes those which have numerical scales as- signed factors, but use definitions determine the relative degrees which each factor affects the particu- lar job. The Rositzke plan perhaps 36—THE IRON AGE, August 24, 1939 the best known example this type, and since this plan intended for use professional engineers, would not expedient have specific lists key jobs under the various factors which might lead prospective cus- tomer think the plan was more adaptable some other business than his own. This omission the job lists gives the impression that the plan more universal, and not limited any one industry. cannot denied, however, that lists comparative jobs are important aids job rating. AND Key The third type plan includes those which have combined the desir- able features both the other types. They use fundamental factors basis analyzing the job, with both relative definitions and lists key jobs aid selecting the proper point value for the job question. There are two outstanding examples this type plan. First, the occu- pational rating plan published the Industrial Management Society and first presented the Midwest In- dustrial Management Conference April 23, 1937, and second, the rating plan published few months later, January, 1938, the industrial relations department the National Electrical Manufacturers’ Association. Popularity the Plans was found that many individual companies had either adopted one these plans directly, had used one them model for plan some- what more specific their own com- pany. some cases the same factors were used, with the same basic defini- tions, but with considerable amplifica- tion more detailed definitions, and more specific examples peculiar their own individual cases. some cases, the point values had been altered correspond with different opinions the relative weightings the vari- ous present the relative popularity these two plans seems about equal. The NEMA, however, has done great deal excellent work developing complete system definitions applicable chiefly, course, the electrical manufacturing industry, rather definite procedure for systematic wage surveys, and generally well organized plan in- this respect, NEMA probably has some advantages over the IMS. Quoting one tive recent developments job evaluation, the Industrial Management Society plan probably the most pretentious and comprehensive work other manufacturer writes, “The NEMA plan seems one the most complete plans available.” And, quoting Dr. Walters, the personnel department Purdue Uni- versity, from his paper job evalu- ation published Mechanical Engi- neering for December, judge from this study, more com- panies are modeling their job evalua- tion systems those two plans than any others.” IMS and NEMA Differences Although these plans are somewhat similar, there are differences. Regarding the number characteristics, NEMA has 11, while IMS has 23. This means that NEMA will grade job probably little more quickly, but the IMS plan gives more fundamental phases the job, and the greater number factors tends equalize errors any one factor. The NEMA five possible classifications under This also contributes toward quicker grading, but lacks the flexibility the continuous scale the IMS plan. The NEMA plan provides for ceil- ing, maximum number points, YOUR ] | | AR 7 | | ° ° ° | i | the lin | pa ] ot su It m St Se | | | | | | thereby limiting the application this plan the range jobs which was originally constructed. The IMS plan has ceiling, and hence not limited its application. NEMA at- tempts measure experience the total learning time for the job. definition for learning time given, however, and indication what part person’s life what stage his experience that learning time supposed begin. the other hand, the IMS plan based the fact that the term can de- many different ways that does not give clear-cut basis for common understanding. More funda- mental factors are used, therefore, such as: Period adapting one’s self new company; specific types satility; each which can adequately defined and easily compre- hended. Sex Color Differentials Another fundamental difference the two plans the policy regarding different wage scales for male and labor. The NEMA plan pro- vides for different wages for men and Women supposedly doing the same work. the classification system difficult show different grades women doing somewhat types work, and casual ob- the jobs might fail any actual differences. With the more detailed consideration the actual jobs made available (and week the author described the operation ranking and point rating plans. this, the second and last section this article, the author first describes the three general types presentation and administration point rating plan. addition, information given sex and color differen- tials, manner installing plan, costs, etc. even required) the IMS plan, ac- tual differences will detected the jobs and the resulting point values, thereby eliminating the necessity different wage scales. certainly not line with American democratic principles pay different wages for exactly the same work (if exactly the same) merely because dif- ference sex color. Corroborating this reasoning, paragraph taken from “report classification and compensation positions the service the Com- monwealth Virginia,” made the Governor, Griffenhagen Asso- ciates, June, 1937, Richmond, Division Purchase and Printing. “Some ground for differences pay between women and men and between white and colored workers was found. But provision for such differences was incorporated the compensation plan because the plan based the classification plan, which founded the basic principle like pay for like work. the applica- tion this principle, the authors this report found themselves entirely unable say that the work posi- tions any class found such and such value relation the values those other classes, should treated worth one rate when performed employee one sex color, and entirely different rate when performed employee dif- ferent one both these respects. The compensation plan thus provides single salary scale for each class positions, regardless the color, sex, ° BARRETT ROGERS Assistant Professor Industrial Engineering, Purdue University ° c other personal characteristics the Generally speaking, the NEMA plan simpler, and therefore probably more quickly and more easily applied, although possibly somewhat limited its scope. The IMS plan more com- plicated, more thorough, and probably more universally applicable. men- tioned before, the manager decide how good job wants done when selects the plan wishes use. Installation Any Plan should value outline the steps required the installation any good plan. Jos The importance getting adequate job descriptions can not emphasized too much. The plan and its application can better than the descriptions the jobs from which works. The satis- factory practice seems send brief questionnaires the individual employees asking them only for spe- cific facts about their jobs. standard form should used which built around the factors used the plan. questionnaire should filled out the foreman wherein asked for qualitative opinions learning time, experience, etc. for the various types jobs his department. Also this gives clue the number different jobs that need rated. These questionnaires are then re- viewed the job analyst who uses them introductions and background for personal interviews with each operator about his specific job. From all these data, the job analyst should then write uniform types job descriptions for rating the jobs. These descriptions should written such manner that they can used readily the personnel man records job requirements for hiring new em- plovees, and perhaps should include THE IRON AGE, August 24, 1939—37 | \- 1, l- le it. ts, suggestions for questions tests re- garding the adaptability the pros- pective employee, also lists specific requirements jobs. Key Regardless the key jobs which may listed the master rating plan, good practice rate few well known jobs and keep them constantly avail- able for reference while grading the remaining jobs. This method has been found save much time when grading questionable jobs, and all cases im- proves the consistency the work. ATING: From the survey, composite opinion seemed that the grading should done committee rather than one two individuals. order cover departmental boundary lines, this committee should headed chief job analyst who, for this purpose least, reports directly the president. The further consist departmental super- intendents, foremen, the personnel men, and representatives the work- men. This sounds like high priced committee for this type work, but from one the large steel mills, where all this work was done the superintendents, came this statement: “Proceeding department time, these conferences and the work analyzing, briefing, and comparing statements preparatory them, re- quired several months. Incidentally, may mentioned that these confer- ences, aside from the work that had direct bearing the rate problem, proved one the most effective and valuable supervisory training jobs have ever done organiza- tion problems, labor costs, like.” which came from several men with long experience this wo