The Iron Age 1939-10-12: Vol 144 Iss 15

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents ( London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham EROY ALLISON toy EDMONDS Newark, N. J. St. Louis TURNER, JR. Buffalo Owned and Published CHILTON COMPANY (Incorporated) Editorial and Publication Office Executive Offices hestnut and 56th Sts., 239 West 39th Sr. Philadelphia, Pa. New York, N. Y. OFFICERS AND DIRECTORS C. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, 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 Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 a year. Single copy, 25 cents. Cable Address, ‘“Tronage, N. Y."’ ADVERTISING STAFF Emerson Findley, 621 Union Bidg., Cleveland B. L. Herman, Chilton Bldg., Phila. H. K. Hottenstein, 1012 Otis Bidg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York 428 Park Bldg., Pitts D. C. Warren, P. O. Box 81. Hartford, Conn Don F. Harner, 1595 Pacifle Avenue, Long Beach, Cal. RON Contents OCTOBER 1939 The Coming Collapse German Industry Metal Cleaning Washing Machine Perchloric Acid Steel Standardization Superior Steel Modernizes Production What's New Material Handling Equipment Weekly Ingot Operating Plant Expansion and Equipment Buying Products Advertised Copyright 1939 Chilton Company (Inc.) t almost century—through wars, panics, depressions and other crises, Industry has come Ryerson for steel. Ryerson stocks have been ample, deliveries prompt. Today you can sure the same dependable service and addition, under the Ryerson Certified Steel Plan you are assured high uniform quality. With Ryerson selected Certified Alloy Steels you get complete data (chemical, physical and heat treatment prop- erties) every bar shipped. large Ryerson plants, carrying more than 10,000 sizes, kinds and shapes steel stand ready meet both your regular and emergency requirements. you not have the current Ryerson Stock List, shall glad send copy. 18—THE IRON AGE, October 12, 1939 RYERSON PLANTS AT: CHICAGO, MILWAUKEE, ST.LOUIS, CINCINNATI, DETROIT, CLEVELAND, BUFFALO, BOSTON, PHILADELPHIA, | q . THE IRON AGE ... OCTOBER 12, 1939 ESTABLISHED 1855 Vol. 144, No. and Bombs have heard good deal about the ingenious development substitutes; they are called, which Germany has developed. materials are substitutes for things that nation has have live fight that are not indigenous and therefore likely cut off war time. Rubber good example. While thus far Germany has not developed substitute for money, her scientists have managed produce from available components great many materials, which money cannot buy now that the blockade effect. But well keep mind that this fact does not solve the war material problem. One can himself into bankruptcy. Take the case artificial rubber. know how make it. But much more costly produce and process, measured man-hours dollars, than the natural product. The same thing true most, not all, substitutes. there were only few materials for which substitutes were required, the situa- tion would not serious. But Germany these materials and products are numbered hundreds. All which raises Germany's cost levels, both living cost and fighting cost, far above the levels her adversaries. And cost level has great deal with the outcome war just has with the outcome business competition. addition the necessity depending upon these materials, Germany, Ex-President Hoover has just told us, sadly lacking many war materials. says Mr. Hoover, for coal, potash and nitrates, does not possess full supply any essential raw material for war. She has partial supply some things, but probably essential raw materials she has pro- duction all. "It impossible store things for long war. Her worst shortages are iron ore, rubber, oil, cotton, wool, copper, tin, nickel and hardening alloys. She has her own synthetic natural resources possibly one-third her needs rubber and oil. cannot obtain outside rubber; she can conceivably secure oil from Russia and Roumania, but not enough wholly comfortable war. iron ores the Allies already have cut off per cent per cent her needs, and full war needs cannot found Russia Central you will keep these facts mind reading the unusual article which starts the following page, you may find the answer why France and England are content play waiting game. may more deadly than bombs the long run! | | ie after reasonable quantity steel sheets have been put through forming and finishing operations after all time losses and rejects are accounted for then, and then only, can you tell how much your steel costing you. Can this cost reduced? You may think saving can made. But why not make sure? Put this question Inland metallurgist, for his business know the answer find for you quickly. surprising number cases Inland Men are able find new economies ways im- prove the result. You will like the friendly way which your nearest Inland Office will co-operate whether you need steel information about it. KANSAS CITY STRIP TIN PLATE BARS PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS ¥ ' economist whose family includes persons now prominent Ger- many here gives his own view- point the ability the Reich’s industry withstand long war. This story, uncensored and car- rying his pen name relieve members his family still Germany from embarrassment, was written following his arrival from Berlin several weeks ago. ILL some section the Ger- man people, its army, church, industry revolt against Hit- ler during the first year the new European war? That unlikely be- cause most the people Germany cannot see the advantage them such revolt. They know that Ger- many can compared with ship Industry with crazy man for captain. The crew, among whom are the millions German people hating and fearing Herr Hitler, would like intern the crazy captain his cabin but there use trying that. Here the reason. The ship has been bad storm and its rudder smashed. navigator longer matters. the captain were sane would not matter. Nobody can steer with the rudder smashed. regime, Herr Hitler’s another, can solve eco- nomic and political problems except through settlement all major prob- lems Europe the same time. The German today must ask him- self these questions Suppose the army officers led revolt against the Hitler regime; would military dictatorship better than the present regime? Would there any more profits, clothes wear food eat? Would there any more what the democ- FELIX BEYER racies call freedom? The answers these questions are “no” and the con- clusion “Why revolt?” What German Industry Faces Clearly the business man Ger- many, who today must consider him- self largely employee the state, subject always the whims overwhelming political bureaucracy, can nothing bring about change. sees German industry with the new European war only started. Its superb industrial equip- ment lacks raw materials and de- clining efficiency because many factors, each vital, each seemingly im- possible solution and removal, and each capable the end bringing about the collapse Germany’s indus- trial system. First, the withdrawal skilled men from industry for service the army, THE IRON AGE, October 12, | ~ ; > 3 & & | | | which relatively new and lacking large numbers skilled officers, has hampered industrial production time when Herr Hitler demanding still greater output. Second, Germany faces shortage everything except coal which forms its greatest single natural resource. short iron ore and machinery, short fuel oil, short copper, wheat, materials which might cause fatal gap the country’s industrial system. Third, the Reich’s workmen are al- ready tired and production per man nearly every manufactured raw material steadily declining. Poor food lessening the German efficiency. German workers are older, average, than workers many other countries because the continued maintenance large army has drawn off the younger men. the coal mines, particularly, production per man has fallen. Fourth, German industry already suffering from what might termed “involuntary sabotage.” The hope- IMPORTS GERMAN INDUSTRY Other ores and slags Copper* crude and manufactured Non-ferrous metals, except copper and tin Gasoline and benzine and steel Steel scrap Machinery, electrical Other machinery Petroleum Gas and fuel oil Coal Tin All imports, including above *187,304 tons 1937 and 300,269 tons 1938. 1937 1938 $89,202,000 90,830,000 94,373,000 49,210,000 59,228,000 66,450,000 61,876,000 53,356,000 48,889,000 35,164,000 41,961,000 33,241,000 39,183,000 12,992,000 6,459,000 6,166,000 10,301,090 14,686,000 10,159,000 10,863,000 24,790,000 33,517,000 24,341,000 27,190,000 12,072,090 10,943,000 $2,188,657,000 GERMAN IMPORTS FROM POLAND (From the Department Commerce) Coal tar derivatives bars and shapes Steel plates and sheets Railroad materials Copper All imports from Poland* 1937 1938 1,339,000 1,358,000 474,000 723,000 211,000 595,000 298,000 716,000 130,000 123,000 $27,274,000 $38,392,000 approximately $23,000,000 food products and $6,384,000 lumber 1938. GERMAN IMPORTS FROM RUSSIA (From the Department Commerce) Gasoline and lubricants Industrial oils and fats Raw chemicals Steel scrap Misc. ores All imports from 1937 1938 $6,027,000 $1,921,000 628,009 1,178,000 1,161,000 243,000 511,000 121,000 112,000 $26,189,000 $19,036,000 *Includes lumber, $5,495,000 1937 and $7,647,000 1938. 22—-THE IRON AGE, October 12, 1939 lessness life the Reich has fened the hands workmen fac- tories and farms and, despite the utmost pressure from Nazi district leaders and the Gestapo, production most articles lags behind consump- tion. Fifth, the necessity developing “ersatz” substances make the Reich’s deficiencies many raw materials, has thrown intolerable burden industry and has lifted costs production absurdly economic heights. For these and other reasons, Ger- mans who see the fatal circle which their industry whirling, dicting the complete collapse industry within four eight foes may know this and may holding off costly attacks upon collapse, not know. Whether Herr Hitler will destroyed from within when the industrial collapse comes, doubt. There one else lead. The circle around which German economy racing goes ever faster. The use inferior substitute raw materials lifts industry’s costs. Then the government must rush state subsidies. make sidies, the government thereupon must obtain forced loans from other parts industries resort the issuance fiat money. These forced loans and lead inflation which means higher prices, which means more subsidies, which results more forced loans and fiat money that the public debt Germany has already reached the dimensions existing the last month the 1914-1918 war. Business Man Should Know USINESS men America who have had keep their heads above water recent years with the weight large political bureaucracy added his other problems will un- derstand some degree the burden under which the business man Ger- many groaning. But American industry has had only taste what government hamstring- ing can be. knows very little the immense difficulties doing business state like Germany. German industry politics everything. Each step which business man takes must approved Nazi party leader with the particular situation which the business leader finds himself, new-equipment needed meet mount- ing costs which the present German economy entails. | i Likewise the workers are helpless. Since the employer struggling be- tween state-fixed wage rates and state- fixed prices, does the German steel worker good even think about demanding wage increase, regard- less living costs. The employer doesn’t have the margin necessary increase wages. doesn’t need worry about wages, because can nothing about them. His biggest worry the politician whom must strive constantly please, whether lift production greater heights find the money subscribe the government’s forced loans ordered help some other industry which even worse circumstances own. Nazi Difficulties Grow You can see that the morale the average German today, whether farmer, unbelievably low com- parison with the morale the aver- age German 1914. Then his lot was relatively happy, his sacrifices the government not unreasonable and the “living space for his soul” not hope- lessly limited. Then there were not the shortages today, least not until the later years the war. Taken one one the difficulties which Herr Hitler finds himself are growing. The advantages now has, such the trade pact and reported military alliance with Soviet Russia, are frequently illusory. seems that the likelihood that Herr Hitler can win long war reduced propor- EXPORTS GERMAN INDUSTRY and steel Machinery ..... Chemicals, advanced Automobiles Other vehicles Copper Instruments, scientific Chemicals, crude Vessels Non-ferrous metals, excluding copper All exports, including above tion its length. Demands the army, for example, the civilian population, have been great. For several years has been necessary keep large army men out in- dustry and fully prepared mo- ment’s notice back the Fuehrer’s political and economic adventures with force. There Germany, con- sequence, distinct shortage skilled 1937 1938 $222,992,000 171,259,000 182,533,000 120,477,000 104,572,000 104,901,000 84,078,000 81,751,000 50,733,000 53,582,006 41,967,000 49,613,000 43,171,000 64,682,000 51,489,000 47,630,000 43,825,000 24,024,000 20,572,000 21,458,000 19,833,000 32,993,000 26,616,000 27,851,000 $2,376,428,000 workmen. The army, which itself highly mechanized, has drawn off many the best mechanics, the result being reduction the efficiency what still may called industry. Productivity Worker Declines the same time the necessity maintaining large force arms has THE IRON AGE, October 12, 1939—23 | 4 ‘ at lengthened the hours work for the civilian population and has reduced their opportunities for rest and recrea- tion. The increase industrial acci- dents and sickness has been marked. That productivity per workman should decline under such situation only natural. However hardy and docile, however great the traditional love the German people for dis- ciplined existence which their lives are directed the state, the hard working conditions under the Hitler regime have reduced production many industries. What the use working hard, many Germans ask? “Herr Hitler will only ask work harder. has already gotten into war that would have ex- cuse issue food cards.” first the German sense humor was sufficient overcome the incon- venience and discomfort wearing, eating and otherwise using “ersatz” materials. They knew armor plate cannot “ersatz” shells from the French 75’s would right through it. But after few years “ersatz” living, now worsened the British blockade for peace, the will the German people (of any people re- gardless their patriotism) grows stronger and their will fight and starve becomes weaker. The increase costs imposed German industry required manu- facture “ersatz” substitute mater- rials staggering. Not even the great technical knowledge and enterprise German industry have been enough overcome the added costs making these substitutes. Artificial rubber can made but the cost great. The man-hours work required pro- duce synthetic gasoline is, for instance, beyond comparison with the costs taking oil made nature out the ground. What Has Reich Trade short “hope,” condition which will demonstrated when the Allies are able inflict the first major defeat the German armies, but the shortage nearly everything but coal equally dangerous. meet this shortage most raw materials the Soviet likely little. Many commentators foreign affairs the United States marveled the (*) That the Soviet government leaders also acknowledge Germany’s inability pay now for raw materials U.S.S.R. was shown Sept. when For- eign Commissar Molotov declared: Soviet government agrees furnish Ger- many all necessary raw materials, for which Soviet Russia will compensated Germany with goods delivered over extensive period.” 24—THE IRON AGE, October 12, 1939 PRODUCTION IRON ORE Metric tons GERMANY POLAND 28,607,903 464,000 2,580,020 280,170 75,787 2,551,185 158,131 4,274,600 243,469 5,948,819 327,074 461,614 763,780 10,969,773 Austria's output. Lorraine and Luxemburg. PRODUCTION COAL GERMANY 118,640,113 104,040,540 125,010,766 158,380,003 months production from Saar. practicality the deal between the Soviet and Germany. mechanized nation, Germany, was making agreement provide its manufactured products exchange for the raw materials which less industrialized country, Russia, had abundance. What could more natural? was “marriage great possibilities.” Yet what has Germany offer Soviet exchange for its wheat, its cotton, its iron ore, its manganese and the long list vital materials which the U.S.S.R. produces.(*) Herr Hit- ler has gold. has excess machinery. When left Berlin, the purchaser any power-driven ma- chine would have been compelled wait year, perhaps two years, for its delivery. The strain Germany’s industry now great that little machinery can exported. Instead German industry would like import machinery, could. Russia cannot count German machinery, any more than can count Germany provide manufactured products. Ger- many has, can shown, shortage almost everything except coal which, course, hopes sell neutrals. Already has been forced ration scores raw materials and finished products and the war has only begun. Germany could export some its technical men Russia help devel- ope Soviet industry, had sur- plus technical men. you believe likely that German industry, al- ready fighting for higher production against obstacles, could spare any tech- nical men? When the situation which the Reich’s industry finds itself question answers itself. Stalin's Victory Was Political Stalin can expect assistance the way highly skilled technical men from the Reich. From study the Reich’s needs and its ability pay for what needs, can shown that Stalin will have difficulties getting anything out Germany that the Soviet requires. Stalin’s victory the Soviet-German trade and mili- tary agreements was more (an opportunity spread Commun- ism) than economic and the Soviet unlikely have the delusion that can paid for providing supplies wheat, cotton and other commodities the quantities needed the Nazi government. Stalin needed Hitler less than Hitler needed Stalin and the fact that Herr Hitler was driven giving half conquered Poland the Soviet and make other concessions which, far, are only hinted at, evidence Hitler’s weakness. And the point greatest weakness Ger- many today industry. Nothing was more potent spur- ring Herr Hitler start war than reached peak productivity 1937 and then began (after standstill) decline from this peak which, con- tinued, might soon bring economic collapse Germany. This condition Herr Hitler sought mask war. Exports Declines War Neared During 1938 the Reich’s export pic- ture, despite effort win trade force, threats force, bartering, blocked marks and other devices, was darkening. Out total lead- ing commodities exported Germany showed declines from 1937 and only eight products showed gains. The eight included exports non-ferrous metals, electric wire and cable, auto- mobiles and machinery. Machine tool exports declined sharply during 1938 did exports coal and chemicals. All along the economic front the Nazi effort expand its foreign trade was meeting failure and making enemies. Nearly every South American country now loaded with marks and rues the day when started trading with Hitler Germany. the same time Hitler’s efforts i | | we | In us In . i In In ar | pr | | | ] | make Germany completely self-sus- taining were making no- great prog- ress and out products imported 31, including copper, iron ore and gasoline, were brought into the Reich greater quantities 1938 than Despite the success German in- dustry developing ersatz materials and collecting and utilizing every usable article, such the iron fences cemeteries and Berlin’s back yards, Herr Hitler the beginning 1939 found himself short almost every raw material. Expansion Ger- man territory has not offset this raw material deficiency. While the Fuehrer overran Poland, including upper Silesia, and seized its industries and resources, French troops and French guns already had halted production Saarland, region whose industry much more important than all Poland’s. The Saar’s steel ca- pacity greater than Poland’s and its mines, although having much smaller capacity than Poland’s mines, produce the best coal Germany and fuel highly superior that produced any- where Poland. Industry Loses Weight, Politics Gain LWAYS Germans have been en- vious foreign oil fields. Oil means more now than ever before. Germans were disappointed learn the fleeing Poles had dynamited the Galician oil wells. Each time Ger- man farmer sees warplane flying overhead, says himself, goes pork and potatoes.” What says literally true. improve its gasoline the German government has been forced use alcohol made from potatoes. Since the potato the chief food for hogs Germany, the hog goes hungry because the plane must have “jacked-up” gasoline. Be- cause the hog must hungry, there are fewer hogs and less pork for the German farmer’s table. Thus the Ger- man does not always say “Sieg Heil” when sees fleet bombers. Fre- quently the German farmer has other grudge against the bombers because the building military air- fields and superhighways throughout Germany has taken thousands acres out cultivation, that the Reich farmers produce less food for civil- ians well for Hitler’s army. This does not mean that there less food for Nazi party leaders who can grow fat the German industrial machine has grown thin for lack raw ma- terials. Interceptions Reich-Bound Materials British Fleet (In tons reported British Ministry Information) Reported Ore 20,000 23,150 Petroleum Manganese Ore 28,500 4,600 20,000 25,700 10,000 14,200 7,200 Molybdenum Aluminum Wolframite 15,500 400 160 6,000 THE IRON AGE, October 12, 4 | od € METAL CLEANING ATCH methods applied pro- duction machine elements the process manufacture fast becoming obsolete. Wherever pos- sible continuous methods adopted. This particularly true plants operating mass production basis—nor has been found decidedly detrimental handling small produc- tion orders. the case metal washing there can and does exist variety patterns which handied through the washer con- tinuous stream without the necessity for change the equipment. Usually, therefore, washing machine can obtained, even for the very small plant, which will solve the metal washing problem satisfactory manner. The deciding factor the purchase this type equipment labor cost productive nature. For instance Technical director, Magnus Chemical Co., Garwood, 26—THE IRON AGE, October 12, 1939 EVENTH Series Articles the Technical Economic Aspects Metal Cleaning and Finishing plant having productive labor pay- roll $100,000 per year can afford washing machine doing the productive labor cost can reduced per cent. Or, look the problem from nearer viewpoint. ex- ample, take the washing the roller races for ball bearing having out- side diameter in. Each these races weigh Hand washing piece-work basis showed cost 10c. per 100 Machine washing showed production 8000 Ib. per hr. Hand washing these would equal $8. Machine washing, using conveyors which the parts were placed the grinder operators and conveyed directly through the mechanical washer, showed 100 per cent elimination the productive labor for washing. True, there was charge for power, washing compound excess that used hand wash- ing, cost for maintenance the equip- ment, and charge for heating the washing solution; however, these all told equaled only small fraction that per hr. productive labor ing. Machine washing may divided into four classifications according the type machine used: (1) The splash method; (2) the spray (3) the continuous feed spray and (4) the continuous feed drum The splash method involves paddle wheels and similar wash the parts. The washing solution preferably used hot, 180 deg. F., and very good washing job usually results. The method some- what slower than when using spray heads supplied with the washing solu- tion relatively high pressures, say per sq. in., but, some troubles encountered with spray noz- zles are not present the splash ma- chine. Because the use paddles there nothing clog the water passage, and solids which would throw the spray machine out commission not bother the splash machine all. the other hand the tendency with the splash machine use the solution with too much solid matter suspension, resulting inferior job cleaning. With proper knowl- edge its limitations, advantages and disadvantages, the owner splash \ ma dit ce j | 1S In 7 | Sf | t | n \ 7 | all J machine can work highly satisfac- tory and save money his cleaning. Fig. shows washing machine the splash type. possesses all the ele- ments modern design, equipped with moving conveyors, uses heated solution where advisable, equipped with ventilation, housed prevent sloppy working con- ditions usually considered unhealthy and general constitutes very ex- cellent piece equipment. Fig. shown the rotating drum head used some splash machines. obvious that nothing can stop this head from doing its work except failure power, which, the way, slightly higher than for the same capacity spray head machine. Spray washers are very widely used. Except for the trouble stop- page the nozzles foreign matter held suspension, they perform ad- mirably, are low maintenance cost, low operation cost and require prac- tically attendant labor produc- tive class when equipped with through conveyor. Since most these types machines are equipped with conveyors they will considered some length. Fig. shown very large washing operation carried the plant Edward Budd Mfg. Co., Philadelphia. The washing machine, which ft. wide and has inside LEFT paddle type washer. Courtesy RIGHT Fis. 2—Rotating drum head used some splash machines. height ft., provided with washing compartment ft. length, rinse section ft. long, dead space ft. long followed second rinse section ft. long, drying section ft. long, which followed the paint spray section. overhead trolley conveyor passes through the entire washer and paint section. This trolley conveyor operates speed 6.6 ft. per min. and provided with variable speed trans- mission capable increasing the speed ft. per min. The wash sec- tion equipped with 120 spray heads rows with heads each row four rows each side the section. Washing solution supplied the spray heads in. Goulds single stage centrifugal pump, directly con- nected hp., 440 volt, phase, cycle, 900 r.p.m. electric motor work- ing pressure Ib. per sq. in. After installing this system siderable trouble was encountered due lint from the parts plugging the nozzles the spray pipes. This trouble was entirely eliminated the installa- tion Cuno Engineering Corp. filter the discharge line from the pump. This was done the wash solution only; however, similar in- stallation under consideration for the rinse section. MITCHELL* The wash tank holds 2200 gal. solution and 150 Ib. non-foaming washing powder added every hr. The temperature the wash kept 170 deg. constant steam coil supplied with live steam 100 lb. gage pressure reduced gage reducing valve. The rinse water kept temperature 150 160 deg. and the drying section held temperature from 230 250 deg. The material passed through the unit consists all side frame bars for truck bodies prior assembly. These parts come the washer with very heavy coating drawing compound. The weight material put through the system 1500 per min. conveyor speed 6.6 ft. per min. and speed ft. per min. The material comes the paint position exception- ally clean and dry providing very excellent paint surface. Inc., located Philadelphia, manufac- turers anti-friction bearings, con- siderable washing parts process done. All washing takes place washing machines operating the batch principle well continuous conveyor handling through the washer. There also solvent degreasing machine use. Cleaning parts here done for several reasons and obtain benefits dependent the stage manufac- ture. For example the heat treat- ing department all bearing races pass through the heat treating furnaces into automatic quenching machines. The parts then way conveyor belt the washing operation for the THE IRON AGE, October 12, 1939—27 q 7 | V- to 7 7 Vv V 7 3—Very large washing operation carried Budd Mfg. Co. 4—Dump- ing parts into tumblast ma- chine for blast cleaning. Last cleaning be- fore polishing parts SKF plant. removal the quenching oil. The washing solution contains soda per gal. water kept temperature 150 deg. This cleaning necessary because the parts then into electric tempering furnaces where the quenching oil, left the parts, would cause carbonization the heat- ing elements. This operation consists the handling 8000 material per hour. Here also efficient handling device for moving the parts between operations. The heat treating fur- naces are the thoroughfare type the finished parts going from the fur- nace direct into the oil bath where they land conveyor which per- mits draining before the parts reach cross conveyor leading the wash- ing machine. The transfer the parts from the cross conveyor the wash- ing machine conveyor accomplished having the conveyors different levels. The parts come off the wash machine conveyor into chute falling into alloy basket used the elec- tempering furnace. This basket holds 600 800 material and when full picked electric hoist operating overhead trolley which the basket lowered into the furnace. The basket again picked out the furnace the same hoist, the end the tempering period, and set the floor front tumblast machine into which the parts are dumped, when cool, for blast cleaning. This latter operation shown Fig. Subsequent washing operations the parts, which there are six, fol- low machining and assembling oper- ations, and are for the purpose cleaning off the oil and grease en- able proper inspections made well remove compounds subse- quent finishing operations. For in- stance the operation shown Fig. follows the grinding and precedes the polishing operation. The grinding done machines equipped with mag- netic chucks, therefore demagnetizer coil used encircling the belt con- veyor which the parts must travel the washing machine conveyor. This results demagnetizing the parts and makes possible the thorough cleaning. The solution used the washer gal. paraffin, gal. emul- sifying agent and 122 gal. water temperature 160 deg. The capa- city this equipment 1000 per hr. The time required pass through the washer approximately sec. The conveyor speed adjustable and since the next operation polish the parts are air blown facilitate Prior going into parts storage, from which place all parts are drawn for the assembly, the parts must given final inspection for finish. This inspection cannot thorough unless parts are all polishing the parts are clean all poli ing compound consisting number 220 cleaning machine grit and tallow the principle ingre- cleans well and dients. degreaser used for this gives cient protection conveyor, each basket holding tion for short Ib. and requiring min. for time. complete cleaning cycle. The machine good solvent action, not fire hazard and permits the parts come out with sufficient protection resist oxidation for short period time. prepare the parts for parts stor- age they are again washed through machine, shown Fig. supplied with through conveyor. This wash made gal. paraffin, gal. emulsifying agent and 178 gal. water. The solution heated 170 deg. lowing the washing operation the parts pass through dryer ft. long and the exit end this dryer they are air blown remove the last trace water. Some moisture remains, how- ever, the bottom surface the part where lays the conveyor and remove this moisture prior the oil spray they pass over heating Fic. plate supplied with electric heating elements. This plate in. square washing machine When the parts come out parts parts storage. storage the oil film must removed washing operation, shown Fig. the washing solution being made with gal. mineral seal oil, gal. emulsifying agent and 400 gal. water. This solution heated 160 deg. The capacity this washer 4000 product per hr. The parts now the assembly benches where they are assembled into complete bearings. Prior packaging for shipment the assembled bearing must washed and inspected. This cleaning done two stages the difference between them being that the cleaning solution the final stage passed through De- Laval separator before being used second time insure that the solution free from all solids which might deposited the bearings and result inferior wearing product. The final washing operation involves solution 100 per cent mineral seal oil. Following the final inspection the they are cleaned te 3 bearings are greased, wrapped oil this washer. paper and packed individual paper MORRIS JOHNSON Chief Chemist Crucible Steel Co. America, Park Works the perchloric acid procedure for the determination metallic iron iron ores reduction with sul- phurous acid (with without the elements Cr, and not interfere, nor does WO, (which filtered out). The procedure follows: 600. ml. beakers digest 0.4 and 0.5 gm. the finely ground ore with ml. concentrated and then cool. Add mg. KCIO,, and boil off the chlorine smell. When residue white, filtered out the quantity considerable. Wash thoroughly, first with 1:20 and then with water. Hold the filtrate and washings, and ignite the insoluble residue platinum crucible. Add the ash ml. 1:1 and ml. HF, and evaporate fumes Cool and rinse this solution into the main filtrate and washings. the latter add 1:1 NH,OH until iron hydroxide starts form, i.e., neutral- ize part the free This solution transferred liter boiling flask and ml. 1.03 1.035 sp. gr. are added, after which the solution will turn red. warm until becomes colorless 200 ml. volume. Then add additional ml. and bring boil and continue boiling with rapid stream CO, passing from pressure cylin- der. This requires about min. fast passage CO,. Keep CO, pass- ing until more SO, can detected, and continue until the reduced solu- tion cold. Dilute with cold water, saturated with CO,, volume 700 ml. Add 100 ml. 1:4 H,SO, and titrate with standard first change gotten two drops solu- tion. This change the first pink tint. appreciable interference filtered out) solution, other than color. Vanadium does interfere and must compensated for adding equivalent amount the standardiz- ing mixtures. The permanganate titrating solu- 30—THE IRON AGE, October 1939 four preceding sections this series articles, the author described the perchloric acid procedure for determining manganese all types alloy steel and iron ore; sulphur steel, coal and coke; and nitrogen steel, ferro-chromium, coal and coke. this, the fifth section the series, de- scription given the use perchloric acid the determination metallic iron highly alloyed chro- mium, sten, and vanadium steels, and per cent nickel steels, ferro-manganese and iron ore. tion prepared dissolving 3.16 gm. which equivalent about 0.00540 gm. per ml. H,SO, water passing the gas from into cold water until the liquid shows gravity about 1.03 1.035. This kept stoppered cool place prevent stopper blowing out with force. Metallic iron iron ore can also high-chromium-iron alloys, using per- chloric acid, described later. The determination metallic iron with H,SO, reduction illustrated the accompanying photo. There shown the reduction flask and the re- moval the excess SO, boiling the solution with rapid stream CO, passing from pressure cylinder. The beaker (3) contains some Na,- CO, cylinder equipped with regu- lator control the speed—this es- sential. The flask (2) contains the solution the iron. High High Alloys The following technique used for the determination metallic iron high carbon-high chromium iron al- loys solution acid-reduc- tion with sulphurous acid water the presence Cr, Mo, and Ti. For example use high-speed steel containing 8.3 per cent Mo, 4.25 per cent Cr, 1.27 per cent and about 1.85 per cent Weigh 0.4 and 0.5 gm. sample 600 ml. beakers, and digest slowly ml. 1:1 hydrochloric acid until action ceases. After cooling add 400 mg. excess, KCIO, and boil off the chlorine smell. Add ml. and fume heavily until all carbides are dissolved. Then cool. Add 100 ml. H,O and boil for min. until free the chlorine smell. Then enough permanganate added produce slight cloud oxide when boiling. Continue boil and add dropwise, until the cloud longer disappears. After cooling, add enough H,SO, just dissolve the precipitate and more, and again bring boil. Cool, again, and add the iron just begins precipitate. Then add until the iron just dissolves. Transfer this liter flask and introduce ml. H,SO; and warm until the color ferric iron disap- pears (volume this stage 200 ml.), chromium present until green solution obtained and for additional min. more. (See pre- vious discussion iron iron ores Connect the flask with gas cylinder and boil with stream CO, passing through, until SO, smell longer exists, which should about min. The SO, coming from the reducing flask passed through beaker containing saturated solution ab- sorb the SO, (see photo). After cool- ing, dilute with H,O saturated with CO, volume 700 ml. and add 100 ml. 1:3 with solution, 3.16 gm. liter, until drops give brown tint; | | ° ° | | ° ° ° | more drops will show pink shade. Standardize the synthetic mixture containing the same amount The Cr, Mo, and take part the reactions except little color interference. This distinct advantage determining total such ferrous alloys. The color effects can easily compensated for the addition pure salts Cr. for ex- ample. The found the sample the foregoing method was 82.35 per this plus 17.38 per cent determined elements gave total 99.73 per cent. The small amounts Sn, Ni, Cu, and certain pres- ent are not included -in Some months later another analyst obtained 82.56-82.68 per cent from this same sample titrating with and diphenylamine indicator also titrating with first pink value 82.41 per cent was determined, Per Cent Nickel Steel This method for the determination metallic iron per cent nickel steel titration has the ad- vantage that vanadium does not take part the reactions. Dissolve 0.4 and 0.5 gm. the drillings 600 beakers, heating with ml. 1:1 per cent strength. Boil down heavy fumes destroy any car- bon, and then cool. Dissolve with 150 ml. H,O, and then boil off the chlorine smell completely. After cooling transfer liter boil- ing flasks, and then add NH,OH until some hydroxide precipitate ap- pears. with concentrated from drop- ping bottle, and then pour ml. 1.03 sp. gr. Warm until all color yellow ferric salt disappears. Boil the solution for min. with rapid stream CO, from pressure cylinder, passing through the flask glass tube two-hole stopper. This set-up used for the determination metallic iron reduction. The mixture CO, and SO, escap- ing through the exit glass tube absorbed flask containing 500 ml. saturated solution sodium car- bonate. Place the flask ice water, and maintain this CO, stream until the solution the reducing flask about the temperature the ice water. The accompanying photo shows this boiling with the CO, passing. Stop the CO,, and dilute 700 ml. with H,O saturated with Add ml. the usual phosphoric acid mixture and drops diphenyla- mine indicator and titrate with stand- ard K,Cr,O; first change color, slight blue. Cr, Ti, Mo, and (the best filtered out before reducing the iron), not in- terfere except color, i.e., there chemical reaction with the dichro- mate standard solution under the con- ditions set forth. The titrating solutions are fol- lows: 39.23 gm. K,Cr,O; dissolved equivalent about 0.0055 gm. iron. 3.16 gm. dissolved equivalent about 0.0053 gm. metallic iron. (Fe 1.2865 FeO; Fe.) The phosphoric acid mixture follows: 1400 ml. H,O, 300 ml. concentrated and 300 ml. per cent phosporic acid solution. The indicator gm. diphe- nylamine dissolved 100 ml. concentrated H,SO,. The following results have been obtained 56.27 and 56.04 per cent titration; and 56.27 and 56.27 per cent titration. THE IRON AGE, October 12, if A 4 i} “= ICKEL SILVER produced from the Mark Twain Memo- rial sculptured Walter Russell for the Hannibal, Mo., museum. Cast the Superb Bronze Co., Brooklyn. ESTHETIC have been applied cemetery design within recent years are responsible for rapid increase the demand for cast bronze grave mark- ers. their uniformity and avoid- ance incongruence, these markers and the improvements that usually ac- company them contribute dignity, sim- plicity and beauty. The essential qualifications for these metal markers correspond closely requirements for ornamental bronze statuary, historic decorative plaques, and architectural castings. They must permit faithful reproduction fine de- sign detail unusually thin sections for their area, and legibility for many years despite attack weather and atmospheric corrosion. avoid sur- face imperfections, plaques are usually cast with the design side the drag lower part the mold. composition which has pleasing red color and being used success- fully for ornamental castings many non-ferrous foundries contains per cent copper, per cent tin, per cent lead, per cent zinc and per cent nickel. The relatively high zinc con- 32—THE IRON AGE, October 1939 CAS TING tent facilitates production sound castings its deoxidizing action. Zinc and nickel, improving the fluidity the molten bronze, help fill all parts the mold and reproduce the design all its detail. Nickel also im- proves color and corrosion resistance. The low lead content, although con- sistent with easy machineability, OLOR simple alloys. The shaded area alloys. reported promote the development attractive oxidized finish after prolonged exposure outdoors. When white plaque required, the nickel-silver casting compositions offer many further advantages. Their resistance corrosion somewhat superior the usual brasses and in- creases with the nickel content. After prolonged exposure without cleaning, patina soft brown green color adheres the surface and protects against pitting further corrosion. practical composition for the produc- tion metallic white castings contains per cent copper, per cent zinc and per cent nickel. moderate range subdued color tints can produced adjustment the copper, zinc and nickel contents indicated the accompanying chart. | | S j | | | ° ° ° cations previously discussed (in Oct. issue) may compared with carefully engineered working drawing, which merely method showing the exact requirements given part. The steel specifications are set for similar reason, that is, definitely establish the physical and metallurgical requirements each grade steel. manufacturer would use mechanical parts vital import- ance without first checking their ac- curacy, because knows from past experience that some inferior parts are made. For exactly the same rea- son material inspection program essential. Some steel will received that does not conform the speci- fications. The specifi- should handled such manner that maximum results will obtained with the least possible effort. Most manufacturers mechanical equip- ment have very limited metallurgical staff and would impractical for such organization check every item outlined the previously men- might well mention that manu- facturers such items anti-friction bearings must not only check all items referred to, but others which were not included this discussion. The aver- HARTLEY Metallurgist, LeBlond Machine Tool Co., Cincinnati age manufacturer mechanical equip- ment primarily interested obtain- ing commercially sound steel with the expected hardenability, and the best possible machinability for the type material involved. Oct. issues, the author presented data and dis- cussions dealing with the characteristics various types steel required machine tool builders, sum- marized recommended group steels, and set forth pical purchasing specifications. this, the final section, materials in- spection program gested, and code system given for indicating vari- ous grades steel and heat treatments records and drawings. Although the following suggested inspection program will not provide check for every item specified, will furnish vital information mini- mum inspection cost. The producer requested fur- nish the following information all standard grades steel prior ship- ment: (1) Heat analysis; (2) Brinell hardness the processed steel; and (3) grain size the heat from which the bars are made. the information conforms the specifications, shipment authorized. After the steel received, thick disks are cut from representa- tive number bars each size. The disks are carefully inspected for de- fects, such seams, pipes and in- ternal cracks. The Brinell hardness Fig. (in Oct. issue). the bars are larger than in. diameter, they cut down the dimensions shown Fig. (in Oct. issue). the steel grade that will used for heat treated parts, hard- ened accordance with the condi- tions outlined the specifications cov- ering the particular item. After the part heat treated the surface “B” (Fig. polished and hardness readings are made shown. cold-drawn samples are involved, the surface decarburization checked THE IRON AGE, October 12, ° ° ° making readings surface “A” (Fig. and comparing them with the readings taken surface the readings are the same, the de- 0.000 in. deep. However, the sur- face “A” softer, 0.005 in. re- moved and second hardness check made. This procedure repeated until the hardness surface cor- responds that surface “B.” may noted from the example inspection high-carbon tool necessitates the use hardenability specimen such shown here. specification No. (in Oct. issue) that partial decarburization allow- able depth 0.010 in. below the surface. However, the writer has found comparatively few shipments steel that did not show full hardness depth 0.010 in. The inspection high-carbon tool steel necessitates the use different type sample from the one used for the other grades. The sample shown TABLE Company, Company, Heat Steel, Symbol Treatment SAE No. Number Symbol Type Heat Treatment X-1314 A2, A3, A4, etc.* Carburizing, single high temperature quench. B2, B3, etc.* Carburizing, double quench. X-1314 C5, C7, etc.* Salt bath treatment. X-1340 Flame harden. 4145 Harden and temper 293 331 Brinell. 4145 Harden and temper 321 363 Brinell. 4145 Flame harden. 4145 Strain-relieving draw. 4145 Normalize. 4615 I3, etc.* Carburizing, single high temperature quench. 4615 J2, J3, etc.* Carburizing, double quench. tool steel Harden and temper 269 302 Brinell. Strain-relieving draw. Anneal. 4345 Harden and temper 293 331 Brinell. 4345 Harden and temper 352 388 Brinell. 4345 Strain relieving draw. 4345 Normalize (controlled cycle). forming Harden and temper 269 302 Brinell. ing tool Strain-relieving draw. steel Anneal. resisting Strain-relieving draw. tool steel Anneal. tool steel Harden and temper 285 321 Brinell. tool steel Anneal. inch for all carburizing treatments. The numerical suffix indicates the depth carburized case sixty-fourths the case salt bath treatments the numerical suffix indicates the case depth thousandths inch. 34—THE IRON AGE, October 12, 1939 For bars smaller than in. diameter, the samples are obtained cutting section in. long from the bar and turning the required di- mensions. Samples from bars larger than in. diameter are obtained cutting thick disk and machin- ing the specimen from it. This prac- tice used avoid any unnecessary waste. The original bar end disk checked for initial hardness shown Fig. before the diameter 3-in. long hardenability sample made. obtain consistent results from the hardenability tests all samples must processed an_ identical manner. The following procedure has been found give very good results: (1) Heat small furnace approxi- Adjust the burners until small pine block smokes and gives off intermit- tent flashes blue flame. The result- ing charcoal should not glow. Set the samples end the central part the furnace. The same number samples should hardened each test and the should used for all tests. (3) Allow the samples remain the furnace for min. (4) Quench per cent sodium chloride solution approximately deg. sufficiently large quenching tank should used keep the tem- perature the quenching medium from exceeding 100 deg. (5) Rough polish the surface the specimen and check for hardness. (6) Notch in. from the end with abrasive cut off wheel and fracture. Take care keep the fractured ends clean. (7) Rough grind one the frac- tured ends flat surface. (8) Check for core hardness. (9) Etch for two minutes per cent solution approximately 160 deg. The fracture, surface hardness, core hardness, and should compared with the require- ments set the specifications. The specimens shown Fig. all show close grain lipped fracture. This fact indicates they all have fine inherent grain size and will with- stand reasonable shock conditions. specimen shows coarse grain frac- ture that not lipped, the stee