The Iron Age 1939-09-07: Vol 144 Iss 10

ine, ron PPLIES ing ‘ing ce Flexible on North North FRITZ FRANK President VAN DEVENTER Editor Editor News Editor Editor Machinery Editor Art Hditor Metallurgical Rditor Associate Editors Washington Editor Resident District Editors Pitteburgh Chicago Cleveland Detroit Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Leroy ALLISON Roy EpMONDs Newark, N. J. St. Louis TURNER, JR. Buffalo Owned and Published CHILTON COMPANY (Incorporated) Editorial and Executive Offices 239 West 39th St. New York, N. Y. Publication Office Chestnut and 56th Sts., Philadelphia, Pa. OFFICERS AND DIRECTORS MUSSELMAN, FRITZ FRANK, Executive Vice-President FREDERIO C. STEVENS, Vice-President JOSEPH Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE, THOMAS L,. KANE, CHARLES 8. BAUR, G. CARROLL BUZBY, P. M. FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations Member Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. 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 Emerson Findley, 621 Union Cleveland B. L. Herman, Chilton Bidg., Phila. Hottenstein, 1012 Otis Bidg., Chicago Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York Warren, Box 81, Hartford, Conn. Don F. Harner, 1595 Pacific Avenue, Long Beach, Cal. Contents SEPTEMBER Twenty One Cents the Steel Choosing Metal Finish Copper Wire Annealed Strands Throw Away the Scrap Barrel California Builds Steel Homes Offerings Motors and Lighting Washington News THE NEWS BRIEF Weekly Ingot Operating Rate Activity Capital Goods Plant Expansion and Equipment Buying Just Between Two Products Advertised Index Advertisers Copyright 1939 Chilton Company - Steel song m +e | | | | | = | | | | 1855 THE IRON AGE ... SEPTEMBER 1939 Vol. 144, No. Cents the Dollar WENTY-ONE cents the dollar. That percentage. And that the that the tax collector extracts from every dollar present day national in- come the United States America. that, are short-changitig For tax collections fall far short meeting the annual expenditures the most wasteful and profligate Administration that America has ever known. paid our bills the the kick back would between and cents the dollar instead cents. are making present the difference posterity. present reverse put correctly. Every man, woman and child the United States averages present day tax im- post $114.09 per annum. And the same token, he, she signs note, addi- tion, for the future payment some $35 per year for the annual present Federal deficit. When you consider that the annual per capita income for 1938 was only bit over $500, this Government check-off means real money. did not dig these astonishing and alarming figures. Who did? The Treasury Department the United States. The Treasury last week issued report the subject taxation, Federal, State and local. Evidently believes good policy this tax matter before the public before the Republicans -1940. And the Treasury Department asking business for suggestions ways and means making taxation less burdensome. Less burdensome the employer and the wage earner. Coincidentally, this appeal business came after the AFL New York State had revealed the wage earners that approximately cents out every wage dollar was being knocked off Uncle Sam. hesitate say told you Prophets, you know, are without honor their own country. But the risk unpopularity, let remind you that year after year have predicted that New Deal extravagance would come home roost upon the shoulders American labor. agree one hundred per cent with President Roose- velt that are paid the sweat every man who And might also add: the suffering and privation every widow who lives upon life insurance other investment income." There one solution this tax problem. Put men power our Government who know what means and what takes earn dollar. And who know how much harder save that dollar than was earn it. Fa. § ~; < 9 4 1 supply sheets with special properties better meet such requirements deep drawing, forming, ing, finishing—and scores others. Inland does this matter course—and co-operates with thor oughness that may surprise you. The chances are good that Inland metallurgists with their broad experience, have already solved WHATEVER PRODUCT you make, your sheet your problems and that they can aid you requirements are peculiar it—exacting. one improving your products realizes this better than does Inland. ing your costs. serving many industries with hot and cold Inland specialist will gladly discuss the mattet rolled sheets, Inland called upon develop with you, without obligation. South Dearborn SHEETS STRIP TIN PLATE BARS PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING be $ . 1 | | recognized fact that very efficient general steel standardiza- tion program has been effect for several years. The purpose this discussion show how much more specialized program established for given organization group organizations engaged the production related products. The series steels known the SAE grades are well standardized for general use over widely diversified field. However, there are over 100 SAE grades generally listed; addi- tion these items there are probably 1000 1500 different trade-name steels the market (not including the stainless steels). have overlapping physical properties, and, the case trade name steels not infrequent find the analyses almost identical. The data Tables next week) indicate some extent this overlapping analyses and physical properties. The purpose specialized stand- ardization program basically two fold: improve the products and the same time reduce the net cost. Both these purposes can definitely accomplished such program. Most manufacturers have set some limitations which their de- must conform. However, not infrequent that large organiza- tions have many overlapping grades steel. This condition particu- HARTLEY Metallurgist, LeBlond Machine Tool Co., Cincinnati larly prevalent where trade-name ma- terials are used. There are very few machines that cannot fabricated satisfactorily from five grades steel. But still, there are bound always parts that necessitate the use special-purpose materials. this reason usually desirable care- fully select approximately five grades special-purpose steels supple- ment the general-purpose materials. The adoption limited number products lower costs, these objectives, are available through the application steel standardization described herein. This Section five-part article. The entire manu- Hartley. this, Section the author presents the characteristics SAE steels most generally used machine tool builders, and sets forth the ef- fects various alloying elements steel. will usually result better product more economically produced. Such program will reduce the total number types cycles heat treatment required. And, naturally, this will result better work because the heat-treater will have better op- portunity study the characteristics the smaller number standard materials handled and will become more thoroughly familiar with any The finished product will further improved be- cause the steel can purchased much more rigid specifications when ordered the larger quantities made possible reducing the number items stocked. Also, the net cost material appreciably reduced be- cause the quantity discounts. For example: The quantity extra applied cold- drawn SAE 4145 steel, when pur- chased lots 300 Ib. less, $2.50 per 100 this drops 20c. per 100 lb. when purchased lots two three tons, and base price when purchased lots five ten tons. addition the quantity extra involved, the smaller purchases are usually made from warehouse which must necessarily add additional handling charge. actual check records has shown example where the cost given steel dropped from $8.77 per 100 when purchased small quantities prior carefully THE IRON AGE, September 1939—27 a | ty : 4 this you ANALYSIS os | = a- 1020 0.20 0.30-0.60 0.045 X-1020 0.20 0.70-1.0 0.045 0.12 0.60-0.90 0.13 X-1314 0.15 1.0 -1.3 0.045 X-1315 0.15 1.3 -1.6 0.045 3115 0.15 0.30-0.60 1.00-1.50 0.45-0.75 0.040 3120 0.20 0.30-0.60 1.00-1.50 0.45-0.75 0.040 4620 0.20 0.40-0.70 1.65-2.00 0.20-0.30 0.040 Turned TABLE Characteristics COLD DRAWN PROPERTIES Can Steel Satisfactorily 3 a 4 o CHART KEY AND GENERAL REMARKS: range +0.04. Carbon range 0.17 maximum. Vanadium, 0.15 minimum, 0.18 desired. Some grades steel are more susceptible defects such seams, pipes, inclusions, etc., than others. This characteristic should studied before selecting steel. The properties all grades steel decrease the mass increases. However, the percent decrease depends the analysis. highly stressed parts are use the mass effect must considered. Warehouse data are approximate and subject revision. Price data are subject revision and sho only used for comparisons. The tabulated temperatures shown this column are only approximate. Uniformity case hardness depends the planned standardization program, $5.33 per 100 when purchased larger quantities after the program was operation. This net reduc- tion $68.80 per ton. Such outstand- ing examples are not typical, but most cases net reduction $15 $20 per ton can consistently aver- 28—THE IRON AGE, September 1939 aged. This would amount saving approximately $5250 per year plant using 300 tons steel bar stock. But, this figure represents only the direct savings material costs. addition, previously stated, the bet- ter specifications which are made pos- sible will result more uniform material, which turn will improve machineability, and will reduce chining costs, machining spoilage and heat treating losses. General Outline The establishment efficient steel standardization program must 7 7 7 7 ~ ( - | | ONE Carburizing Steels Core Properties In. Section, High Temperature Quench Oil Water Required for the Given Steel (HT) Core Properties, In. Section, High and Low Temperature Quench Oil Water Required for the Given Steel CASE PROPERTIES | Complete Size Ranges Steel Stocked (Warehouse) i burizing and hardening technique employed well the characteristics the steel. should exercised select steels that can satisfactorily treated with available apparatus. the corners machineable when the carbon and manganese are the high side the anaiysis range? N—No able under ordinary conditions. Y—Yes. carefully considered from several ob- jectives, namely (1) The general types steel re- quired for parts fabricated from bar stock and forgings. (2) analysis the physical and the various types. C.D.—Cold drawn. (3) analysis the relative merits and net costs the various types bar stock finishes. (4) The establishment purchas- ing specifications. (5) The establishment mate- rials inspection program. (6) The establishment code H.R.—Hot Rolled. not machine- quenched from the proper core refining re-heat temperature and not directly from the carburizing box. H—The corners can only machined under favorable conditions. L—Limited stock available. system for each the various grades steel and for each heat treatment. Each these six objectives will considered detail: the first objective, types rials generally required are considered. The requirements each the vari- ous types steel are outlined and six THE IRON AGE, September i | : a $ 2 7” 77) | — = > ome car- ‘AV ‘ove and ~ q j : | TABLE General Purpose 0.45 1.60-1.90 0.45 0.60-0.90 3.25-3.75 0.45 0.30-0.60 1.50-2.00 0.90-1.25 0.45 0.50-0.80 1.50-2.00 0.50-0.80 0.30-0.40 0.45 0.60-0.90 0.50 0.60-0.90 0.50 0.50 1.60-1.90 0.50 0.60-0.90 3.25-3.75 0.50 0.30-0.60 1.50-2.00 0.90-1.25 5150 0.50 0.60-0.90 6150 0.50 60-0.90 CHART KEY AND GENERAL REMARKS: Sulphur, 0.075 0.15. However, the 0.80-1.10 revisions and should only used for comparisons. 30—THE IRON AGE, September 1939 ata not available. N—No. The physical properties all grades steel decre cent decrease depends the analysis. Warehouse data are only approximate and are subject revisions. L—Limited stock available. ase the mass increases. Price data are subject C.D.—Cold drawn. H.R. rolled. 7 7 - as 100 Per Cent Engineering Steels Physical Properties Fine Grain As—Quenched, As—Quenched, Machining Range for Average Steel, Hardened and Tempered Sections the Sections the Complete Size Production Work 400 deg. In. Diameter Section) Following Sizes: Following Sizes: Ranges of: average values from available published data. 1112 can usually turned surface speed approximately 160 ft. per min. N—The listed this column are based constant fatigue tensile ratio factor. has been this ratio factor not constant for steel above 450 Brinell fatigue tests would probably not result values excess 100,000 Ib. per sq. in. for any the steels involved. The values tabulated merely ate the trend. THE IRON AGE, September q es. : ed. tabular charts are reproduced. These charts, tables, give the analyses and some the physical characteristics each type steel considered. addition these tables, very brief tabular presentation the end this article shows the effect most the alloying elements the physical and metallurgical properties steel. (Herein and Sept. issue.) the second objective, the general requirements each the various types steel are discussed and con- sidered general manner. This portion summarized listing tabular form recommended group steels which felt would suit- able for all requirements encountered most plants that manufacture me- chanical equipment such machine tools, etc. (To appear Sept. issue. the third objective, the various types bar stock finish are consid- ered; the relative commercial toler- ances are outlined, and the economic advantages using the various finishes are illustrated concrete examples. The economic advantages reducing the number finishes and sizes absolute minimum thoroughly discussed. Round, square, flat and hexagon stock are considered. (To appear Sept. issue.) the fourth objective, general outline the properties which should definitely specified are mentioned general manner, and typical pur- chasing specifications are shown and discussed detail. (To appear Sept. issue.) the fifth objective, the necessity well planned materials inspection system discussed and suggested program, which can economically applied, outlined. (To appear Oct. issue.) the sixth and final objective, the advantages using code system for indicating the various grades steel and heat treatments drawings and records are considered. suggested code system briefly outlined. (To appear Oct. issue.) Types Steel Required necessary carefully analyze what types steel are required for parts fabricated from bar stock and forgings, what available and the net cost each type considered. Each the above items must thoroughly expanded cover the many detail problems involved. clearly point out some these problems, hypo- thetical program will discussed. plant engaged the manufacture 32—THE IRON AGE, September 1939 mechanical equipment such ma- chine tools, etc. generally requires the following types steel: CLASS I—General Application Steel (Stock Materials): (1) screw stock; (2) low-carbon low-carbon- manganese carburizing steel; (3) me- dium carbon medium carbon man- ganese steel; (4) alloy oil-hardening steel; (5) alloy carburizing steel; and (6) high-carbon tool steel. CLASS Application Steel (Purchased requirements stocked very limited quantities) (1) alloy oil-hardening steel with higher alloy content than (4) above; (2) non-deforming oil-hardening tool steel; (3) shock-resisting alloy tool steel; (4) abrasion-resisting alloy tool steel; and (5) high-speed tool steel 18-4-2 plus molybdenum type. The selection the grades steel outlined requires very careful analysis the available items. assist making this analysis six tables have been prepared. attempt has been made show the major charac- teristics the SAE grades involved and tabulate some the more prominent trade-name tool steels the types considered. should thoroughly understood that tabulated data this type cannot show all the many variables that may en- countered. However, the tables show some average expectancy values and may employed helpful guide. Tables and show the analyses and physical characteristics the SAE steel most frequently employed machine tool buiders. has been necessary leave many the col- umns blank only partially filled in, either because the data not available because was not deemed advis- able make unrestricted tabular statement. That is, for example, Tables and under the columns “Can Steel Successfully Turned, Formed, Drilled, Tapped, Threaded,” result that might considered satis- factory one plant would unac- ceptable another. However, such columns were included the chart because the factors involved should considered. Effect Alloying Although the effects the various alloying elements are rather complex and inter-related, very brief resume the general results caused the addition each may helpful the analysis data shown Tables published next week.) However, must emphasized that this informa- tion only general and frequently cannot apply, especially the cages more complex alloy steels. CARBON: (1) Hardness increased; (2) yield point increased; (3) tensile strength increased; (4) ductility de. creased; (5) impact decreased; (6) machineability decreased; (7) wear resistance improved; and (8) ing temperature decreased the eutectoid, usually about 0.80 0,9 per cent carbon depending the type steel. steels not considered): (1) Hardness increased; (2) depth hardening in- creased; (3) yield point increased; (4) tensile strength increased; (5) hardening temperature decreased; (6) critical hardening rate decreased; (7) soundness steel improved because manganese acts deoxidizer and tends counteract the harmful effects sulphur; and (8) distortion hardening decreased. PHOSPHORUS: (1) Generally harmful the grades steel con- sidered this discussion; (2) in- creases yield some the low- carbon grades; and corrosion resistance some the low-alloy steels. SULPHUR: (1) Machineability in- creased; and (2) physical properties decreased (within certain limits the harmful effects can offset the use manganese and/or molyb- denum). SILICON: (1) Depth hardening properties improved with the addition small amounts, for instance 0.10 0.50 per cent; (2) impact improved (when used proper combination with other elements, shown Table IV); (3) grain growth in- creased; (4) hardening temperature increased; and (5) rate decarburi- zation increased. NICKEL: (1) Hardness increased; (2) depth hardness increased; (3) strength increased; (5) ductility in- creased; (6) impact increased (most nickel-steels have range that should avoided speci- fying heat treatments) (7) machinea- bility decreased; (8) hardening tem- perature decreased; (9) hardening rate decreased; and (10) rate grain growth elevated tem- perature retarded, especially when present alloys with chromium and/or molybdenum. CHROMIUM: (1) Hardness creased; (2) depth hardness creased; (3) yield point increased, (4) tensile strength increased; (5) ductility decreased; (6) impact de- cré 7 7 tel 7 Vi — creased (temper brittleness encoun- tered some grades chromium and chromium-nickel steels); (7) ma- chineability decreased; (8) hardening temperature increased; (9) critical hardening rate decreased (higher chromium steels are air hardening) (10) wear resistance improved; and (11) hardness high temperature im- proved. MOLYBDENUM: (1) Depth hardness increased (2) yield point in- creased; (3) tensile creased; (4) tensile strength ele- vated temperature increased; (5) ductility increased; (6) impact in- creased; (7) machineability (at high hardness) improved; (8) hardening temperature slightly increased; (9) grain growth elevated temperature retarded; and (10) weldability not affected (probably the only alloy added steel that not harmful the welding characteristics). VANADIUM: (1) Increases hard- ness (when quenched from sufficiently high temperature permit solution vanadium carbides) (2) depth hard- ness, (a) decreased when quenched from temperatures which not dis- solve vanadium carbides due the fact that vanadium steels have fine inherent grain size, and (b) increased when quenched sufficiently high permit solution strength increased; (4) impact in- creased; (5) stability high tem- perature improved (higher vanadium alloys high-speed steel increase hardness 900 deg. 1200 deg. F.); and (6) cutting properties im- CONVEYOR PACKAGING REDUCES ERRORS recent installation con- for packing automotive replacement parts boxes has greatly reduced errors and speeded output the Ashland Road plant Thompson Products, Inc., Cleveland. Two fabric belts, each about ft. long, with variable speed drives, have been installed, integral with tables made stainless steel. The depart- ment well lighted new General Electric fluorescent 40-watt Part the layout and equipment may seen the accompanying photo. Items packed are laid the tables along the belts the proper order their insertion into the boxes. the boxes pass the belt, each girl packs the part assigned her. Formerly one girl packed all required proved (in highly alloyed steels such the high-speed tool steels). TUNGSTEN: (1) creased; (2) depth hardness in- creased (3) tensile strength increased (4) hardening temperature increased (5) critical hardening rate decreased (6) rate grain growth high tem- perature retarded; (7) stability high temperature improved; and (8) wear resistance improved. COBALT: (1) Impact decreased; (2) hardening temperature (3) maximum hardness high tem- perature increased; (4) stability high temperature improved; and (5) decarburization hardening increased. Ed. Note:—Next week the author con- tinues with tabulated data and sions the types steel required for machine tool work. parts each box, slow process with many errors resulting. Bolt assemblies, which consist separate items, can now packed the rate 800 1100 per hr., and single item boxes are packed the rate 2000 per hr. While the girls work one belt, parts are being placed along the other belt for another packing assignment. Shackles are assembled the belts and tightened with air chuck. Tap- ing boxes facilitated through the use newly developed automatic taping machine. John Wagner, superintendent the building, has also developed number special type tote boxes and trailers facilitate handling. THE IRON AGE, September a the 0.90 type nese (5) (6) and on- in- the in- the the Every finishing problem bounded certain funda- mental considerations. This article recognizes these considerations and sets down guides for choosing the proper finish for any particular metal product. ADOLPH BREGMAN Consulting Engineer, New York ° ° finish must first aid the product satisfying the fullest extent its pri- mary requirements, and then aid the others far possible. Without exception, the first require- ment any article proper func- tioning. The product must the work for which intended. Gener- ally next order durability, fol- lowed appearance and cost. course cases abound which price appearance the factor which closes the sale, but this condition obtains where the other factors are about equal competing articles. general rule, therefore, the or- der importance these require- ments for different types metal goods may listed Table The fact that the order these functions may specific instances affected certain variables—a highly its simplest terms, the salability metal product depends upon four factors: (1) Function. (2) Durability. (3) Appearance. (4) Cost. The order importance these factors varies with different types and classes work, but all them are al- ways present; and, varying degrees, depending upon the class and design the product. But, almost always some extent least, each these fac- tors affected the finish. For that reason, more important task con- choice the most suitable finish. Metal products are seemingly endless variety: Consumer goods, in- dustrial products, necessities, useful accessories, luxuries; and large number instances, the boundaries between these classes are hazy. (Is that outstanding metal product, the Nevertheless, they are susceptible orderly classification and close exami- nation will generally disclose the group (1) Function which specific article belongs. (2) Durability each class the order importance (3) Reasonable cost the four requirements given above (4) peculiar itself, but all classes the Necessities 34—THE IRON AGE, September 1939 Useful Accessories (1) Function (2) Durability (3) Appearance (4) Reasonable cost special product, the existing market price range competing articles, the locality which used, the habits the buyers, and even general eco- nomic conditions—makes necessary allow for possible exceptions the knowledge that times depression, the factor cost climbs high the scale importance. Although the consumer continues demand “qual- ity,” the number sales price rises rapidly. not uncommon practice developing new line consumer goods, first set price, based the conditions the market (slightly over slightly under the competitors’ fig- ures, the case may be) and then design and develop the product fit within that range. also well known that the growth “style” has brought the factor appearance much closer the others weight, even the necessities. industrial products there little variation the primary requirements. They are utilitarian, and like the prod- uct the finish must also primarily utilitarian. Consequently, satisfactory operation and durability above appearance and even cost. Still, even here occasional exceptions must allowed. The factor appearance beginning make itself felt and, course, the cost ever-present problem. Finish for Consumer Necessity the experienced designer, the following, perhaps over-detailed anal- ysis may seem elementary. the individual steps listed will often TABLE Requirements Metal Products Luxuries (1) Functioning (2) Appearance (3) Durability (4) Reasonable cost ON 7 : P d 7 Is g a n ‘ | ‘ 7 len. taken simultaneous- ly. However, for the purpose complete- ness, they will set down here sequence. good example consumer necessity the lawn mower, generally made steel throughout. Its service involves rather severe physical handling, often abuse, and also exposure moisture. clearly utilitarian product and the demands the user may, therefore, listed the following order im- portance. Function. (2) Durability. (3) Reasonable cost. (4) Attractive appearance. fulfilling these requirements the order given, the finish must pro- vide for protection against rust; must adhere firmly, without chipping, flaking peeling, under the numerous shocks and other forms mishandling incident the use lawn mower; should inexpensive the market competitive; and should also presentable appearance, although this factor has always been considered the least important. satisfy these prerequisites possible choose from wide variety finishes commercially which are listed! (in alphabetical or- der) Table IT. Beginning the process elimina- tion, possible rule out immedi- ately, for self-evident reasons, chem- colors (not durable enough), clad metals (cost), electrolytic oxides (no aluminum used), lithographing (not durable enough), polishing only (low resistance), porcelain enamels (danger chipping under rough han- Adapted from the chart shown the first article this series entitled, “Metal Clean- cially available, omitting those which have been applied only experimental fashion, even successfully, and those which have made ittle commercial eadway date. IXTH Series Articles the Economic Aspects Metal Cleaning and Finishing dling), rubber coats (cost), cementa- tion coats (brittleness), sprayed metal (too expensive for small parts), vapor coats (cost). This leaves the follow- ing which might used: Chemical rust-proofs, hot dip coats, organic coats and paints. Table III these finishes are listed order comparative effectiveness, un- TABLE Types Finishes Commercially Available Cementation coats: Zine (Sherardizing) Aluminum (Calorizing) (2) Chemical colors: Oxides, sulphides, etc. (Generally require covering with clear lacquer.) Chemical rustproofs: Oxides, phosphates, etc. (Parkerizing, Bower-Barff, etc.) (4) Clad metals. (5) Electroplates. (6) Electrolytic oxides: aluminum and Al- zak). (7) Hot-dip coats. (8) Lithographing. Organic coats: Lacquers, synthetic enamels, includ- ing undercoats chemical rust- proofs. (10) Paints: Including undercoats chemical rustproofs. (11) Polishing (only): High luster scratch, brush, etc. (12) Porcelain enamels: Including art enamels. (13) Rubber coats. (14) Sprayed (15) Vapor coats: Including cathode sputtering. der each the four primary requirements, for the type service peculiar lawn mower. Table III excep- tion may taken the order listing some instances. For example, under durability, the first four are close to- gether. Changes design will often affect the cost electroplating. Under appearance, the first two finishes listed might easily shuffled, depending upon taste the designer. And need- less say, combinations all these finishes can used, with numberless possibilities. From examination Table III the reasons are clear for the usual choice paint, for this highly utilitarian ob- ject. With paint finish the mower operates satisfactorily with any other finish. low cost. Long life, under the abuse which this machine subjected difficult for any finish achieve, and attractive appearance has always been the last consideration. (The next step, deter- mining the type paint, the pigment, vehicle, etc., another problem, the detailed analysis which cannot considered here, for lack space.) The changing attitude manufac- turers, however, well illustrated most original solution this par- ticular problem which has been offered lawn mower built Clemson Brothers, Inc., Middletown, Y., whose machine made entirely steel and die castings (except for the wooden roller). The handles are steel tubing with chromium plated grip. Chromium plate used the knurled knob for adjusting the bed knife; also the roller adjustment lugs, the tie tube and the name designs the wheels. The handle, wheels and gear housings are finished baked yellow enamel. Durability finish achieved plating the same thick- nesses required the highest grade automobile work and the baked finishes THE IRON AGE, September the non ion, the the ual- ises tice mer the ver fig- ght the ttle its. ily far ill, ust he ~~ al- TABLE Ill Comparative Effectiveness Finishes for Lawn Mower this instance the distance these requirements greatly ished, the first three being extremely paints, rubber coats and sprayed met als. (Clad metals, theoretically, with- this group may written off mediately the grounds cost; also cementation coats which are not close together. Appearance, though and the cost often pressing sideration. Consequently, every found: Electroplate, chemical colors and organic coatings infinite ety. The functioning the radio side finish; the life the instrumen The cost also determined large extent the construction the strument itself. The purpose finish therefore mainly Where protection from rust provided the decorative finish plied sufficient thickness. Asin the case the costume jewelry, there fore, the choice limited the tive finishes. But again, within this group, the possibilities are finishing this motion picture projector, electroplate able and the decision rests entirely and organic coatings are combined for protection and the skill and taste the designer, Industrial Finishes are applied the same fashion the portance than most other classes industry everything used the standard automobile body finishes. merchandise; sells the desire plant may classed the buyer and its own distinctive useful accessory. The few luxuries Finishes for Luxury Product style. The requirement uppermost which may found are rarely The best example out-and-out mind (taking satisfactory part the operating equipment, luxury consumer product is, course, operation for granted) appearance. but are likely consumer jewelry. Taking the example, spe- advisable eliminate once for use the offices, etc. So, almost cifically, item low medium all finishes except those which are the without exception, the order priced costume jewelry, made brass, most decorative: Chemical colors, elec- quirements follows: the requirements order (including electroplated col- tance are follow: ors), organic coats and art Function. And this point the analysis must (2) Durability. (2) Appearance. stop the choice again rests (within (3) Low cost. (3) Durability. the price range) upon the taste the (4) Appearance. (4) Reasonable cost. designer, who may use any one any The first example come mind this instance, the first prerequi- group these finishes combination. industrial necessity the ma- site again satisfactory operation. Al- The possibilities are practically chine tool. this instance the first though the demands service seem ited. two requirements are very close slight (even cheap jewelry handled less extreme example with the third, cost, much less with some care), they must met; product the radio, which the order important and appearance bad last. the piece must hang together and requirements changed to: The primary function the finish main the place where attached. Satisfactory operation. protection against rust. Durability secondary importance (2) Durability. chosen entirely service, which the roduct may outmoded be- (3) stricts the choice chemical rust fore Cost less im- (4) Low cost. proofs, hot-dip coats, organic aug Functioning Durability Reasonable Cost Appearance erally applicable large pieces.) The Protection from rust, Organic coats Chemical rustproofs others are either too expensive the only requirement, Paints Paints Organic coats der varies with Hot-dip coats Paints sufficiently protective. Hot-dip coats Organic coats Hot-dip coats effectiveness under each Chemical Chemical Rustproofs given Table IV. Table explains the general 36—THE IRON AGE, September 1939 Stee q q 4 q et ween dimin. Temely con- colors Vari- itself, in- the this tirely the in- ment, ducts paint the grounds fair dura- low cost and fairly good appear- ance. [ts durability lower than some other finishes but easily and inexpensively replaceable that its use logical. However, even necessity, which appearance still the least consideration, now feeling the influence style. Some machine are now fitted with plated trim improve their appearance and stim- the user take better care the tool, thus adding its life and im- proving its operation. Another utility product, fundamen- tally industrial character but made for the use the individual, shows even greater extent the influence style. Air conditioning units for the householder are coated with lacquers and enamels, often wrinkle finishes and also with chromium plated trim. accessory consider plant instrument temperature controller. Here the service the finish calls for resistance industrial atmosphere, over wide range. Some places are fairly clean, but others subject instruments much dust, heat and fumes. Functioning and durability are far the most impor- tant. The finish must first all pro- tect the instrument keep satis- factory operation, must last, and al- though cost far below these factors LATING for trial chromium used here chemical drying drum. Photo from hromium Corp. America, Waterbu ry, Conn. Las 4 TABLE Effectiveness Finishes for Machine Tools Durability Sprayed metals Rubber coats Paints Hot-dip coats Organic coats Chemical rustproofs Reasonable Cost Appearance Chemical rustproofs Paints Hot-dip coats Organic coats Sprayed metals Rubber coats Functioning Organic coats Paints Chemical rustproofs Hot-dip coats Sprayed metals Rubber coats Protection from rust, the only requirement, varies with durability. TABLE Effectiveness Finishes for Industrial Instruments Durability Reasonable Cost Attractive Functional Aid Organic coats Appearance Protection from rust, Paints Paints Electroplates the only requirement, Hot-dip coats Organic varies with durability. Hot-dip coats Organic coats Paints Chemical rustproofs Hot-dip coats Chemical plates are the most likely chosen. Most instruments this type are fin- ished paint, lacquer enamel pig- mented synthetic, often plain black wrinkle finish, with plated trim. The name plates, course, are fin- tractive appearance obviously the least consideration. Consequently, advisable rule all finishes which fragile, not highly protective, too out expensive, for instance cementa- tion coats, chemical colors, clad met- als, electrolytic oxides aluminum, lithographing, polishing only, porce- lain enamels, rubber coats, sprayed ished the usual fashion etching, plating and covering with clear lac- quer. Finish Functional Aid metals and vapor coats. This leaves chemical rustproofs, electroplates, hot- Since none the examples cited above have illustrated the functional aid improvement operating char- acteristics which might imparted the use heavy chromium deposits, machine parts subject heavy dip coats, organic coats and paints. this group the order under the four re- Table shows that paints, organic coatings and electro- 3 4 7 7 7 HIS designed mainly for decoration. vlectroplating, chemical coloring and lacquering used. Photo from Light- olier Co., New York. wear and corrosion, like pump shafts, washers and plungers Caterpillar Here the finish plays most important part the functioning the machine; must durable, its first cost unimportant because its savings machine wear, and its ap- 2See THE IRON AGE, May 18, 1939, 76. 38—THE IRON AGE, September 1939 pearance moment whatsoever. Only glance the list finishes required see that chromium plate the only one choose for this pur- pose. Another outstanding example the use finishes functional aids the use clad metals for resistance very severe corrosive wear condi- tions, especially for plant equipment where the first cost secondary im- portance, the overall cost being re- duced the lengthened life. Still another interesting functional aid aluminum paint which, when ap- plied the outside furnaces, re- duces the heat radiation and improves the operating efficiency the fur- naces; and also roofs buildings reduce the heat conducted into the building from the sun. very recent example the use finish for functional purposes the gold plated drying and heating re- flector used Ford and made the Hall Lamp Co. The gold plate, stated, has such high efficiency for reflecting infra red radiant heat that, use for baking synthetic enam- els reduces the time drying industrial accessory which the DRASTIC change lawn mower construction and finishing. Electroplate and baked enamel are used and die cast- ings. (first) cost has very little bearing salability. Conclusion Limitations space course pro- hibit illustrations analyses for all the finishes available. however, that the method outlined the choice metal ishes applicable almost any lem. set perfect and all-inclusive standard procedure for choosing the “right” finish for any and all clearly impossible. The multitude products, the infinite variety de. signs and the number processes and materials available for finishing, make necessary keep any plan sched- ule extremely flexible character. rule can written which will not have number exceptions. Nevertheless, bounded certain fundamental con- siderations. analytical approach and orderly, perhaps first even elementary, procedure will often keep the manufacturer from overlooking omitting possibilities, and may suggest finishes which will improve the pearance, add the life, decrease the cost improve the functioning his product important extent. ¢ . \ » 3 ANNEALED TINNE copper wire continuously strands has been made practical through new joint development the Syncro Machine Co., New and the Surface Combustion Corp., Toledo, Ohio. Referring the accompanying il- lustration, the wire unwound from the spool the right, passes over push-pull capstan, through mechan- ical cleaner, and then through the an- nealing chamber. For tinning, the wire then passes through uniformly applied under pressure The tin entirely enclosed, reducing oxidation losses absolute mini- mum. Excess tin retrieved and the wire burnished high luster leaves the tinning zone, self-clean- ing wiping device. bright annealing and tinning Quenching takes place circulating water, the excess water being removed WIRE CLEANER INGLE strand machine used for bright anneal- ing annealing and tinning cop- per wire. The stand- strand machine. highly efficient vacuum wiper. The wire then passes through visual indicator which constantly shows and controls the degree anneal. This device makes possible extremely accurate and uniform control ob- taining the desired percentage elongation. The take-up motor driven and provided with traverse. The spool drive automatically maintains correct tension throughout the filling spool. The spooling tension can ad- justed while the unit operation. The unit can used for either tin- ning straight bright annealing. The annealing chamber consists merely special open flame burner with sheet metal hood protection against drafts. ANNEALING POT WIPING TRANDS The flame continuous and ft. long depending the gage the wire. The burner specially con- structed produce flame uniform height along its entire length. The wire carefully guided through the’ reducing portion the flame eliminate oxidation. This principle bright annealing the same used the large continuous direct-fired furnaces for annealing wire coils and which the burners are set slightly rich produce reduc- ing atmosphere. The elimination expensive furnace and other contributing factors said make this method anneal- ing annealing and tinning copper wire, drastically cheaper than any other method. VISUAL ANNEAL INDICATOR PUSH-PULL CAPSTAN THE IRON AGE, September ed, ive the cts i ide ich yen the his BURNISHING DEVICE one cold drawing shop recently shape, like the one shown Fig. 12, caused end trouble attempting draw and hold specifications. The steel being drawn was tough, dense tool steel that was impossible anneal below approximately Rockwell B-90. The specifications called for diameter 0.499 in. plus minus 0.001 in. The angle shown was deg., minus nothing plus min. The com- plete angle was below the center line the shape, which fact was respon- sible for most the trouble en- countered, both the building dies, and, its location, causing tendency for the free end the bar while draw- ing assume spiral motion. Thus there was created extreme heat both the bar and die. One leg the angle, shown was located directly the center line the shape, there be- ing variation allowed 0.001 in. above the center line and in. below. Special stress was placed the requirements that all corners were sharp and free from scratches. hardened, ground lapped gage made within the tolerances al- lowed was furnished the customer and any bar not fitting this gage tight was rejected. This situation necessitated drawing the lengths approximately ft. avoid stretching, which would affect the fit between the bar and the 40—THE IRON AGE, September 1939 The difficulties encountered drawing this shape were very similar those the shape previously de- scribed (last week) and many re- spects were more serious. The shape, being relatively small diameter and made steel very difficult handle, had potentially apparently unlimited eccentricities. gage. After the break-down, which leit 0.020 in. draft for finish-drawing, attempt was made draw the shape center bearing solid die. (See issue Aug. 3.) The first few bars were within the desired limits and had all the appearances perfect job. Just about the time everything ap- peared solved, things commenced happen. drawing perfect bars, the next bar started scratch the junction the angle and the radius and before the bar machine could stopped the bar was badly ripped. examination showed the die badly “ringed,” and one the small projections angle was badly torn, extending nearly the size point the die. The was removed. and repairing the damage the projection was necessary shorten considerably length. changing the length this one projection the die was thrown out balance—that is, the bar longer made even contact with the drawing surfaces the throat the die, the result being that the next bar drawn was badly twisted resembled cork-screw. Thus became necessary reverse the die, which was done; then more bars were drawn before the die was ruined both projections being practically ripped out. dupli- cate the die was made and so-called production resumed. This die de- livered bars before being ruined beyond repair, and this number bars was made possible only constant attention the part the die maker, removing the formed after every two three bars. Finally, the only thing show for three weeks labor the cold drawing department were two ruined dies and bars steel weighing approxi- mately 138 applied against order 5000 This trouble Nearly four months were spent trying every conceivable surface and coating the bars, endeavor develop surface condition conducive longer die life. Some improvement made this direction but not enough offset the failure the die-makers, who during this time had tried every known style solid and sectional dies without success, and desperation were trying any and everything that even remotely resembled die. But matter what the die, the ever present “ring” was found the base the angle projection, and ways the problem remained the same —by repeatedly removing the ring the die would either thrown out balance, rendered short lived; the “ring” was not removed the jections would ripped from the was then decided depart tirely from the accepted standards cold drawing. Casting around for ideas, the construction series very small thread-rolling dies for the typewriter industry While these dies embraced drawing principles, nevertheless they did produce beautiful 60-deg. accurate 0.0002 in.—and angles were responsible for the present dif- This line thought ficulties. 7 7 7 ‘ ° ° => 4 7 aes 7 7 7 > 7 7 7 q 7 q bars stant aker, after for wing and ainst ning. ating velop ough kers, very dies ation that But ever the al- same the pro- die. for the cold they dif- led | directly the turks-head die some- times used for cold rolling shapes. ray hope was seen, and became simple matter combine the prin- ciple the turks-head die with the cold drawing die—thus new-type die, shown Fig. 12, was born. The top and bottom dies, and Fig. 12, differed from the sectional dies previously described (last week), the respect that the surfaces that would normally support the concave and convex radius were ground The hardened and ground dowel pins which also served axis for the angle roller-dies turn on, were used means keeping the dies proper relation with one another. After the dies had been squared up, they were strapped to- gether and the dowel pin holes bored their proper pre-determined loca- tion, Next, two temporary dowel pins were placed the holes just bored; and, placing shim the proper thick- ness between the dies permit grinding the dies after hardening, the 0.499 in. hole was bored, leaving 0.010 in. stock for grinding pur- poses, accurately located between the two dies and the correct position relation the center distance between the dowel pins. After hardening the dies, light cut was made across the sur- face each die provide parallel surfaces, and the dowel pin holes were lapped smooth both the same size and pins fitted them. Then, re- assembling the dies, the throat and drawing surfaces the hole were and polished the proper drawing size. After this operation, the bottom die was ground until the absolute center line the hole was reached, completing dies and The amount stock removed grinding was added the thickness the shims that had been used throughout the construction the dies, and new hardened and ground shims shown were made this new measurement. The 90-deg. angle rollers were hardened and ground all over the correct dimensions, leaving 0.0007 in. clearance between design and construction sectional dies for cold drawing steel were described detail last week. Herein, the second and last section this article, the author con- tinues with detail new type break-down die, and includes data coatings for drawing and other elements the prep- aration steel for drawing. the dies and the rollers after the shims were place and the die assembled die frame such previously de- scribed (last week). This die proved success from the outset, the shape drawn having clean sharp corners and showing perfect fit the gage, with sign twist. Friction was practically eliminated, which fact allowed speeding the job. Furthermore, the length the bars being drawn was increased ft. without any harmful results. less than week, far the cold draw- ing department was concerned, the job was completed. Not once was the die removed from the bar machine. New Type Die Not long ago there was introduced die maker, without doubt one the best the industry, new method constructing solid break-down dies that simplicity itself and positively eliminates any possibility the bars’ being drawn with high-corners either the break-down finish-draw. ever costly, patience-exhausting problem long standing was neatly solved, this was it. describing this new construction, the writer will use example the hexagon center bearing die (see article Aug. issue), which shown containing the throat and bearing sur- faces used breaking-down bars finish draw in. diameter. When making this type die, the die maker proceeds previously described making the regular center bearing die (see Aug. issue) the point where the die ready harden. After the die hardened, the die maker will u