The Iron Age 1939-10-26: Vol 144 Iss 17

FRITZ J. FRANK President J. H. VAN DEVENTER é Editor c. E. WRIGHT J. A. ROWAN A. I. FINDLEY = a Managing Editor News Editor Editor Emeritus Fe Machinery Editor Art Editor Metallurgical Editor Associate Editors Washington Editor a3 Resi T. C. CAMPBELL Pittsburgh JAMES Cleveland dent District Editors BINGHAM Chicago SHERMAN Detroit Editorial Correspondents London, England FRAZAR Cincinnati Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco SANDERSON Toronto, Ontario ASA ROUNTREE, JR. Birmingham Chestnut and 56th Sts., Newark, N. J. St. Louis TURNER, JR. Own Buffalo ed and Published by CHILTON COMPANY (Incorporated) Editorial and Publication Office Philadelphia, Pa. Executive Offices 259 West 39th St. New York, N. Y Contents OCTOBER 26, 1939 Birds Without Wings; Spiders Without Legs Hot Galvanizing Phosphorus Steel Polishing Technique for Stainless Steel Use Carboloy Tools Cars Replete with Die Castings OFFICERS AND DIRECTORS C. A, MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President Job Lot Aircraft Stampings FREDERIC C. STEVENS, Vice-President JOSEPH 8S. HILDRETH, Vice-President On the Assembly Line 48 GEORGE H. GRIFFITHS, Vice-President EVERIT B. TERHUNE, Vice-President WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOUN H. VAN DEVENTER, JULIAN CHASE, THOMAS L. KANE, CHARLES 8. BAUR, G. CARROLL BUZBY, P. M. FAHRENDORE Washington News THE NEWS BRIEF Weekly Ingot Operating Rates Rate Activity Capital Goods BAUR, General Advertising Manager DIX, Manager Reader Service . Plant Expansion and Equipment Buying Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed the Industrial Arts Published every Thursday. Subserip tion Price: United States and Dos sessions, Mexico, Cuba, $6.00; Can nuda, $8.50; Foreign, $12.00 a year. ] : Single copy, 25 cents. Cable Address, ‘‘Ironage, N. New Industrial Literature Robert F. Blair 621 Union Bldg., Cleveland +. L. Herman, Chilton Bidg., Phila. H. K. Hottenstein, 1012 Otis Bidg., Chicago Hi. E. Leonard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York 128 Park Bldg., Pitts D>. C. Warren, P. O. Box 81. Hartford, Conn Don F. Harner, 1595 Pacific Avenue, Long Beach, Cal. Just Between Two 101 Index Advertisers 122 Copyright 1939 Chilton Company (Inc.) | a 3 ui 8 Ryerson Has Thousands Tons Stock for Immediate Shipment Especially now, when steel deliveries are somewhat uncertain, good know that Ryerson has large and diver- sified stocks certified steel hand for quick shipment. Thousands manufacturers every line are daily drawing these stocks meet current requirements. Ryerson imme- diate warehouse shipment forms cheap insurance for the protection your production schedules. Check and play safe your steel requirements. Ten large Ryerson plants, carrying more than 10,000 kinds, shapes, and sizes steel and allied products, stand ready meet both your regular and emergency needs —and you will get Ryerson certified quality extra cost. you not have the current Ryerson Stock List, shall glad tosend copy. Joseph Ryerson Son, Inc. Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, and Jersey City. 20—THE IRON AGE, October 26, 1939 5 3 4 ‘ ) 4 dA anal A ¢ | ... THE IRON AGE ... OCTOBER 26, 1939 ESTABLISHED 1855 Vol. 144, No. Birds Without Wings Spiders Without Legs these motorized days, mobility primarily depends petroleum. The operation large number motorized vehicles, machines diesel engines driven gasoline oil calls for adequate supply fuel. Fuel the limiting factor. The United States has per cent the world's motor cars and produces within its borders per cent the world's crude oil production. Regardless the American automobile ability make cars the millions, would not have them these numbers did not have petroleum readily available. And conversely, did not have many cars, our petroleum producing and refining facilities would not well developed they are. Motorization and petroleum production travel together hand hand. well keep this fact mind considering America's military defensive posi- tion. For modern warfare very highly motorized business which calls for tremendous quantities motor fuel. With our one automobile for every four persons, would not require much civilian gas rationing provide adequately for motorized air and land force any size that could would build. And that despite the fact that our flying and crawling engines war are tremendous compared with our 29,485,680 motor cars and trucks and its ratio one every four persons, Germany has cars and trucks one every persons. Russia has 672,952 one such vehicle each 252 population. Russia, most these vehicles are public service and are not privately owned. Obviously there comparatively little gasoline had these tries restricting the use private cars. Germany has petroleum resources but makes gasoline from coal and potatoes. Her capacity has probably been stepped since the war, but previously was given 30,000 barrels day. This compares with our United States gasoline produc- tion about barrels per day which course not our full capacity. Obviously Germany must import tremendous quantities oil gasoline supply her heavily motorized military machine. Russia her main dependence this matter. But while Russia rated crude oil production about one-seventh ours, she lacks refining capacity. That why German engineers are hurrying Russia. But even given refining capacity, there arises the problem transportation. There are pipe lines from Russia Germany, nor anywhere near enough tank cars even the Russian and Ger- man railroad gages were the same, which they are not for the great majority lines. But even these difficulties are surmounted, Stalin will control Hitler's gasoline supply and through Germany's mechanized birds and spiders. | 4: | bat ia INLAND Sheets YOUR requirements you buy steel, think terms your product—your particular forming opera- tions—your manufacturing methods. What consti- tutes the right steel for someone else may not all the correct steel for your purpose. Inland think steel the same way—an individual matter—a product made fit your pre- cise needs. INLAND PLATE BARS PLATES STRUCTURALS PILING RAILS You see the result that attitude the Inland Cold Rolled Sheets. Their exact con- formance specifications, their superior finish, theit dependable forming qualities are painstakingly built into them—from selection raw materials, through- out each step melting, heating, rolling, finishing. More and more steel users, they learn this prin- ciple custom-fitted sheets, find profit and tion doing business with Inland. TRACK ACCESSORIES REINFORCING BARS a4 ST. PAUL ST. LOUIS KANSAS CITY hot galvanizing process has always been constant study produce increasingly uniform, adherent coatings give long and satisfactory service life. Great improvement these coatings has come from better understanding the importance careful prepara- tion the work prior its being placed the molten zinc. Fortunate- ly, has also been learned that the precautions which lead improve- ment quality also lead lowered costs, largely through reduced wastes. The necessity for removing iron oxide any form from the work well understood because the molten zinc will not attach itself securely these oxides. Such cleaning gener- ally accomplished pickling acid, most frequently sulphuric. Some products, notably castings, are regu- larly and satisfactorily being galvan- ized immediately after sand shot blasting, without pickling. Galvanizers are now aware that not sufficient remove this iron oxide merely changing iron sulphate iron chloride Quality coatings low cost require that iron sulphate chloride kept out the zinc kettle. This precaution has led greater care well the use better methods and materials, the work for the zinc kettle. Pickling General pickling practice use sulphuric acid, usually from BALDWIN Chemical Engineer, Hanson-Van Winkle Munning Co. produce uniform and adherent zinc coatings steel, careful and proper pre-treatment the steel and correct usage the flux wash and fused flux. The preparation and control flux likewise are detailed. per cent (by volume) strength and continue additions new acid the tank until the iron (Fe) content the pickle reaches amounts exceed- ing per cent. Then the pickle acid thrown away and new batch prepared. Some pickling done cold acid but the major amount done 140 deg. over. Iron sulphate, being more soluble hot solutions than cold, generally allowed accumulate greater amounts hot pickles. There common belief that fresh sulphuric acid does not pickle quick- contains some iron sulphate. Often, therefore, part old pickle re- tained and the new pickle built from it. This point debatable, but the light modern experience, should not favored. The important point that the higher the iron sulphate content the pickle, the more difficult becomes completely remove the drag-out from the work the sub- sequent rinsing. Best practice calls for the use the weakest sulphuric acid practical and discarding this pickle more frequently, thus avoiding high iron sulphate con- tent and more difficult rinsing. Each plant must determine its own work, just how weak the acid may accomplish thorough pickling within the required time, but brief study plant’s annual consumption acid generally reveals the possibility making changes acid strength with- out affecting the cost the pickling rate adversely. Rinsing Rinsing after pickling the next step where high quality low cost greatly influenced thoroughness. The best practice transfer the work from the hot sulphuric acid pickle cold, freely-running water rinse before the work dries, and should kept the cold running water until also cold. the work dries air after leav- ing the hot pickle assumes first greenish cast and eventually brown color, first ferrous and finally THE IRON AGE, October 26, 1939—23 are i g * 4 Fé: ° ° ° pigs = “d ‘ | ferric basic sulphate film forms. amount rinsing water will re- move these films and their formation must avoided. This calls for maxi- mum speed transferring the work from the hot pickle the water rinse. Cold water, running freely, the best rinse because the rinsed work also, when ready transferred the flux wash, must not dry off, since will acquire oxide hydrate type rust which invariably follows dry- ing this stage. Agitation the work during rins- ing always helpful. Agitation running cold water has proved most effective way secure the re- moval any pickle acid iron salts this acid from the work gal- vanized. The older the pickle acid and the higher its content iron salt, the more necessary use running cold water and work agitation. The cold water should flow freely enough that the rinse water film left the work contains minimum iron salts. The object rinsing remove the pickle solution from the work, not merely dilute it. Avoid rinsing still which, reality, may merely dilute pickle. The reward for this care rinsing greatly lowered dross production and smoother, more ductile and adher- ent coatings. (Table shows data illustrating the lessened dross forma- tion resulting from effective rinsing accompanied the use zinc am- monium chloride flux wash and kettle flux. These data are current operating figures for malleable iron pipe fittings plant which galvanizes approxi- mately 20,000 fittings hr. They reflect mostly what careful rins- ing will do, although the use better type zinc ammonium chloride flux and flux wash was involved the change from the old operating practice the one used when the new process data were being accumulated. The dross figure 9.8 per cent weight fittings galvanized (186 per ton fittings) while high, not exceptional with product where the more common figures vary between 130 and 200 per ton fittings galvanized. All castings this plant are acid pickled prior rinsing and fluxing. “yield” meant the pounds castings galvanized per pound zinc used. the higher yields the castings had oz. per sq. ft. average coat- ing and showed over four immersions the Preece test. The actual surface area the fittings galvanized during each period has important influence the dross produced and explains 24—THE IRON AGE, October 26, 1939 the variations between the three new process tests. The Flux Wash The older practice using hydro- chloric acid flux wash probably grew out the necessity for correct- ing the weakness the casual and in- adequate rinsing performed many shops. Something had done with the films basic sulphates hydrated oxides that appeared work. Converting them chlorides seemed the answer because continuous coatings fair adherence were obtained. Such hydrochloric fluxed work could dried before dip- ping assure safe handling. appeal- ed, therefore, largely because was the easy way things, although the dross production was high and the coatings peeled easily the most expected and inconvenient times. this method the work gal- vanized coated with film iron chloride. When placed the molten zinc this film must removed before the will coat the iron (that is, alloy with the iron). Removing the iron chloride film the flux fusion the molten provides iron form dross. Likewise, the more chloride there removed, the thicker and more brittle the final zine coating. The answer these objections hydrochloric acid flux wash sub- stitute for water solution ammonium chloride. The zinc monium chloride flux wash places yan” protecting film over the rinsed surfaces and thus delivers them, clean, the molten zinc. The result material drop dross formation and decided improvement zinc coating adherence and illustrates this improved adherence which follows replacing the muriatic acid flux system with zinc ammonium chloride system. The zinc ammonium chloride flux wash can varied concentration suit the type work being done. preferable use wooden tank, and heat it, using either lead Monel metal steam coil. Heating speeds the operation, causing the evapora- tion excess moisture from the flux also providing greater safety handling. Pre-heating the work also reduces the operating time galvaniz- ing. drives out absorbed hydrogen taken the work pickling, which further improves the smooth- ness and adherence the coating. The zinc ammonium chloride wash places film new, flux-pro- ducing material over all work sur- faces, which assures fluxing, especially inner surfaces The Flux Fusion Sal ammoniac (ammonium has long been the preferred material produce the fused flux the molten zinc. The objections were the heavy fumes, its short life and the loss spelter with which combined produce the stable fusion the kettle. was realized that the actual fusion produced sal ammoniac was reality ammonium chloride, TABLE Dross Data for Malleable Pipe Fittings Galvan- Per Cent Dross izing Days Spelter Weight Lb. Yield, Method Work Pot Pot Production Lb. Old Long average ....... 70.0 9.8 7.0 New 42.4 9.2 9.7 seemed logical start with this compound itself, rather than pro- duce high cost from sal ammoniac and the zinc the kettle. Sal ammoniac breaks down, that gives off fumes, about 345 deg. Zinc ammonium chloride does not fume until reaches about 650 deg. F., its use leads reduced fume trou- ble. This characteristic has led some however, when used flux wash and also produce the fused flux the kettle, the result overall actually faster zine coating the work. The most effective zinc ammonium chloride flux contains about per cent zinc, and major part the zinc the flux skimmings comes from this source and not from the spelter. Experience also shows that requires from per cent less zinc ammonium chloride than sal ammoniac the same work flux. Some Practical Results This discussion might summar- ized saying that high quality gal- vanizing -at low cost follows partly from careful pickling and complete rinsing secure clean work, which kept this preferred condition the use zinc ammonium chloride flux wash and kettle flux. Attention these points leads reduction the iron introduced into the kettle and permits better control the iron solution the molten The alloying the zinc the basis metal more rapid, thus reduc- ing the time the work needs remain the kettle, which also means less iron taken into solution the molten zinc, well thinner layers the brittle alloys. The production smooth, adherent, ductile coats accomplished mostly attention these points. What otherwise would lead the pro- duction acceptably adherent coating can spoiled neglecting attention the immersion time the molten Micrographs commer- cial hot galvanized pipe will show increase alloy layer thickness with time and after, say, three minutes there will discernible erosion. the basis metal the hot zinc; also. ° (Above Tensile test for ad- herence zinc pipe. (Below) galvan- ized pipe, showing adherence zinc coating rup- ture pipe. THE IRON AGE, October 26, quite likely thé micrographs will show vertical lines indicating typical shrink- age cracks the coating the iron content the alloys increases. After the immersion time limits for product have been established, has been found practical check plant performance means the simple tension test observe whether the zine coating adheres firmly the point rupture the test piece. Fig. shows two views such test pieces hot galvanized pipe from regular production, where the immersion time has been held closely about sec. zinc 860 deg. This pipe prepared with the close attention the pickling and rinsing precautions just discussed. then allowed soak hot zinc am- monium chloride flux wash for half hour and then enters the zinc kettle. Fig. shows slightly enlarged view the pipe surface the point fracture. The zinc coating has parted with the stretch the basis steel but still firmly adherent the steel. flaking the zine coating 26—THE IRON AGE, October 26, 1939 has occurred. The other view Fig. shows the basis steel immediately underlying the area shown the left. Similar cracks appear the basis and indicate that the cracks the zine coating resulted from the pulling apart the steel base. Similar results are available modern thin wall electrical conduit. The manufacturer this type TABLE ZINC AMMONIUM CHLORIDE DENSITY [Data Deg. (68 Deg. Grams Salt Lb. Salt 100 c.c. Deg. One Gal. Baumé Solution 3.26 3.73 deg. change temperature affects the Baumé reading about 0.029 deg. Baumé. product can check immersion time and any time from the production line produce test piece such that low magnification will show slight parting the zinc the top the bend, and, after stripping, parting the basis steel directly under the same area. But there flaking the coating under this severe treat- Another product which smooth- ness, ductility and adherence the coating primary importance strip steel. And again the same care pickling, rinsing, and fluxing leads the accomplishment the same type result. Fig. shows hot galvanized cold rolled strip 0.025 in. thick and the flexible cable housing being made from it. all cases, without regard the nature the product being dipped, the observance these rather simple precautions the hot galvanizing technique leads high quality zine coating. Preparation Flux The author considers the best type ammonium chloride for gal- When free iron white; need not contain over about per cent water moisture. The of Vv iron Also flux Mon sulat and chlo and prec The flux wash tank should made wood lead-lined steel keep Also, any steam coil for heating the wash should made lead Monel metal and have electrical in- sulating joints inserted the feed and drain lines avoid trouble from stray currents. The zinc ammonium chloride flux wash electrolyte and stray currents may lead quickly coil corrosion unless the foregoing precaution taken. The flux wash prepared simply dissolving the desired amount zinc ammonium chloride crystals the proper amount water pro- duce the final volume flux wash needed. Dissolving zinc ammonium chloride water causes the volume increase; consequently, if, say final volume 100 gal. needed, some- what less than 100 gal. water must used. Generally, when the flux wash contains less than zine ammonium chloride per final gallon, start with water volume equal per cent the final volume desired. When the final salt content lies be- tween and Ib. per gal., use water equal per cent the final volume desired. For concentrations excess per gal. use water equal per cent the final vol- ume desired. Table will serve guide making zinc ammonium chloride flux washes. illustrate use the data Table assume that flux wash approximately 18.7 deg. Baumé den- sity desired. Such solution, when made, should contain 2.73 zinc ammonium chloride per final gallon. prepare 100 gal., therefore, dis- solve 273 lb. ammonium chlo- ride crystals gal. water. These amounts need not absolutely exact serve all purposes within limits because these flux washes per- form satisfactorily over rather wide ranges concentration. The salt dis- solves easily and quickly cold water although faster with heat. soon the crystals are dissolved the flux wash ready for use. General experience has shown that preferable use the flux wash room temperature when galvanizing thin gage sheets sheet metal wares. Caution necessary the case (CONTINUED 91) THE IRON AGE, October 26, 1939—27 ¥ a steels were made with 0.25 per cent having base composition 0.12 per cent 0.65 Mn, 0.10 Si, and 0.04 The first one had low phosphorus (0.004 per cent), and the other 0.16 per cent Vanadium similar molybdenum that ap- pears compatible with phos- phorus. tested here sheet form ran 80,000 per sq. in. tensile strength, and over 65,000 per sq. in. yield strength, with per cent elongation in. for the normalized condition. The Charpy values the bar stock were for both annealed and normalized conditions. raising the phosphorus content from 0.004 0.16 per cent the base composition, and the carbon from 0.10 0.14 per cent both the yield tensile strengths were increased considerably. This shown the tabulation properties this series steels, Table II. application for patent has been filed which included the steels this series, the atmospheric corrosion tests the vanadium the first steel appeared moderately beneficial, while the addition phosphorus materially im- proved the atmospheric corrosion re- sistance that the 0.18 per cent steel Series “B.” Series The first pair steels this series was similar the silicon steels series except that these contained per cent Si. The base composition for this series was 0.06 0.08 per cent 0.50 and 0.04 The first steel contained 0.012 per cent and the second one 0.175 per cent The properties both were satisfactory both sheet and bar stock. yield strength over 50,000 Ib. per sq. in. was obtained with tensile strength about 70,000 Ib. per sq. and elongation in. over per cent. The Charpy value the high-phosphorus was satisfactory even the annealed condition. The addition 1.0 per cent this latter steel produced material increase both strength and yield strength while re- taining adequate ductility and notch toughness the Charpy test. Increasing the carbon from 0.08 0.15 per cent increased the tensile strength still further, about 90,000 Ib. per sq. in. this case the elongation in. was per cent for 28—THE IRON AGE, October 26, 1939 the 22-gage sheet and per cent for the bar stock. The Charpy value the annealed bar stock was ft-lb. the very low-carbon, high-phos- phorus steel the combination 1.0 per cent each copper and silicon seemed particularly beneficial the steel used the annealed condition. The atmospheric corrosion again showed the benefit high-phos- phorus content. Series (Fe-P-Cu-Cr-Si) This series included analysis that close one which used for popular low-alloy steel. The base com- position the series was 0.15 per cent 0.60 Mn, 1.05 Si, 0.97 Cr, 0.37 Cu, 0.04 and 0.016 this phos- phorus was added bring the totals 0.12, 0.22, and 0.32 per cent, give series four steels. The tensile strength the bar stock increased from 80,000 100,000 Ib. per sq. in. and the 22-gage sheet from 70,000 90,000 Ib. per sq. in. result the addition 0.32 per cent The yield strength was in- creased the same amount, about 20,000 Ib. per sq. the yield strength ratio was increased the addition phosphorus. This com- mon experience with steels this low-alloy type. The ductility values were reasonably satisfactory, even for the steel with highest phosphorus, which case the elongation in. was per cent and the reduction area, Metallurgists, Battelle Memorial Institute ° ° per cent. The notch behavior the normalized steels was also satis- factory, though this was not true for the annealed steels containing 0.22 and 0.32 per cent The resistance atmospheric cor- rosion was also excellent. This was true even the low-phosphorus com- position which was definitely superior low-carbon steel with 0.17 per cent but the steel with 0.12 per cent and even more the steel with 0.22 per cent showed additional im- provement total corrosion the 3-year period and deceleration the rate corrosion due phosphorus. Corrosion the latter steels during the last year had virtually stopped. Series The base composition this series was 0.14 per cent 0.60 Mn, 0.10 Si, 1.10 Cu, 0.21 and 0.63 Ni. Two steels were made containing respec- tively, 0.014 and 0.17 per cent Again phosphorus was found exert pronounced strengthening effect and with but relatively small lowering the ductility the normalized con- ditions. The tensile strength the 22-gage sheet was raised from 82,000 98,200 Ib. per sq. in., and the yield strength from 54,800 65,600 Ib. per sq. in. and the elongation in. was reduced only from per the phosphorus. Phosphorus duced the Charpy impact value the bar stock but not dangerously so, for the annealed condition. ‘4 this, the second and final section two-part article, comprehensive data are given for the effect phosphorus additions the corrosion and physical prop- erties number low- alloy steels. Last week the authors detailed ef- fects for mild steel, and for Fe-P-Cu, Fe-P-Cr, Fe-P-Ni, and Fe-P-Mo alloys. The addition phosphorus the base composition improved the resist- ance atmospheric corrosion the end the 3-year period per cent. The low phosphorus base com- position, which approximates that for one the low-alloyed, high tensile commercial steels, showed the same rate corrosion did the low-carbon 0.17 per cent steel series “B.” The corrosion resistance such steel, according the test results, can thus further benefited higher phosphorus contents.. Series series four steels was made with the following base composition: 0.14 per cent 0.60 Mn, 0.10 Si, 0.64 Ni, and 0.04 The first pair con- tained 0.38 per cent and the second pair 1.23 per cent Cu. The first steel each pair contained 0.014 per cent and the second 0.17 per cent give low-phosphorus and steel each composition. Similar Series Series also alloy steel. The properties all steels tested were satisfactory for both sheet and stock. The high-copper steel with high-phosphorus gave over 80,000 Ib. per sq. in. tensile strength, while the yield strength the bar stock was over 60,000 Ib. per sq.in. and the sheet stock was over 69,000 Ib. per sq. in., combined with elongation in. and per cent respectively. The Charpy values were satisfactory, even for the annealed condition. the atmospheric corrosion tests the high-copper, low-phosphorus nickel steel was about good mild steel containing 0.17 per cent while the addition phosphorus this steel improved still more. The effect nickel and copper appeared addi- tive the low-phosphorus steels. The actual corrosion loss after the 3-year period for the four steels this series and two the steels the “B” series are summarized Table III. Series (Fe-P-Si-Cu-Sn) The effect small tin addition was studied Cu, Cu-P, and Cu-Si-P steels. The base composition was 0.13 per cent 0.65 Mn, 0.21 Sn, and 0.04 which were added (1) 0.36 per cent Cu, (2) 0.36 per cent and 0.16 (3) 1.12 per cent and 0.17 and (4) 0.36 per cent Cu, 0.94 and 0.18 Tin acted strengthener (1), though but with little effect the ductility and notch behavior. The same was found true for (2), though the particular steel studied was exceptionally weak the annealed Charpy test. This was not true for similar Cu-P steel without the tin. Steels (3) and (4) this series showed the same notch sensitivity the Charpy test and appears that tin reinforces the tendency phosphorus produce this effect although the normal ductility still high level. Except for this characteristic, all three these phosphorus steels were found good quality. The atmospheric corrosion tests de- veloped nothing unusual. Raising the phosphorus content the 0.2 per cent Sn, 0.3 steel from 0.014 0.17 per cent improved the corrosion re- sistance moderately. The tin, copper, low-phosphorus steel was in_ itself quite resistant corrosion, being better this respect than plain copper plain tin-bearing steels. Silicon did not improve the corrosion resistance tin, copper, phosphorus steel. Series This series developed one compo- sition with very fine mechanical prop- erties and excellent resistance atmospheric corrosion. contained four steels, based 0.50 per cent Mn, 0.90 Cr, 0.10 Si, and 0.04 The first steel contained 0.43 per cent with low phosphorus. The second steel was the same the first with 0.18 per cent The phosphorus this steel raised the tensile strength about 12,000 Ib. per sq. in. both the bar stock and sheet but had effect yield strength. This lack effect phosphorus yield strength dif- ficult account for view the normal effect phosphorus this property. The second pair steels this series contained 0.85 per cent and here the addition 0.17 per cent appears decidedly beneficial. With 0.07 per cent and simple normalizing treatment 1625 deg. this steel developed tensile strength 80,000 Ib. per sq. in., yield strength 58,500 Ib. per sq. in. and elongation in. per cent, and Charpy value ft-lb. Normalizing this steel 1725 deg. reduced the prop- erties slightly. The tensile properties the annealed steel ran about the same, while the Charpy value was still the atmospheric corrosion tests the decelerating effect was pro- nounced that the rate corrosion between the second and third year was only per cent rapid that found for mild steel. These steels were almost identical their corrosion re- sistance with those for the low-carbon copper steels series “F,” corrosion loss curves for which are shown Fig. (published last week). Accord- ing the current tests, the chromium had measurable influence the corrosion losses for steels series “R.” This interesting observation view the fact that one the commercial low-alloyed steels (com- position represented series has the same amount chromium, copper, and phosphorus the steels series and addition has 0.5 1.0 per cent Si. apparent that silicon alters the corrosion behavior the chromium, copper, phosphorus steel considerably, although this would not anticipated from the effect silicon observed other types steel THE IRON AGE, October 26, 1939—29 | ; + : - § + 3, TABLE Physical Properties Phosphorus—Vanadium Steels, Series Analysis, Per Cent L-1 0.10 0.65 0.10 0.004 L-2 0.14 0.65 0.10 0.162 Tensile Yield Type Strength, Strength, Material Lb. Per Lb. Per Tested Sq. In. Sq. In. 0.23 Bar 47,000 Stock 61,000 Stock Sheet Elong. Charpy Heat In., Per Cent ment N-1 A-1 N-2 A-2 N-1 A-1 N-2 A-2 Normalized hr. 1725 deg. F., A-1 hr. 1725 deg. F., furnace-cooled; N-2 normalized min. 1650 deg F., air-cooled; A-2 box annealed hr. 1350 deg. F., furnace-cooled. and particularly those containing chromium. Silicon and chromium when together even minor quanti- ties appear add greatly the corro- sion resistance the low-alloyed steels. Series Four steels were made for this last series with base composition 0.10 per cent 0.45 Mn, 0.22 Mo, 0.04 and 0.04 The first pair steels contained 0.77 per cent and the second pair 0.31 per cent Cu, while the first steel each pair was low phos- phorus and the second ones contained 0.18 and 0.17 per cent respectively. Studies the mechanical properties showed the normal improvement tensile and yield strengths resulting from increasing the phosphorus con- tent. The high-phosphorus steels had excellent ductility and notch impact values both the normalized and an- nealed conditions. Their low suscep- tibility notch brittleness anneal- ing, due probably the molybdenum, was significant. The resistance at- mospheric corrosion steels this series was also satisfactory. The base steels after 3-year exposure showed corrosion losses that were per cent less than for low-carbon low-phos- phorus steel. Adding 0.18 per cent the base stcels improved the corro- sion resistance point where was per cent better than for low-carbon steel the same phosphorus content. Summary Results This investigation brings out several beneficial effects phosphorus alloying element the low-carbon steels. These may summarized follows: (1) The tensile strength and strength plain and alloyed steels both increased with the addition phosphorus. Due the more pronounced effect the yield strength, the “yield ratio” in- creased, compared with mild steel, with the result that increases the amount useful available strength the steel. (2) With low-carbon steels, both plain and alloyed, this increase strength can secured with but little sacrifice static ductility. Thus the air-cooled condition secured values for elonga- TABLE III Corrosion Tests For and Series Composition, Per Cent Corrosion Loss Years, Mg. Per Sq. Cm. P-1 0.14 0.60 0.10 0.64 0.015 P-1 0.14 0.60 0.10 0.64 0.175 P-3 0.14 0.60 0.10 0.64 0.014 P-4 0.11 0.60 0.10 0.64 0.175 0.13 0.58 0.09 0.008 B-2 0.12 0.09 .... 0.169 Annealed Normalized Average 0.38 60.8 56.5 58.65 0.38 42.7 42.60 1.23 52.8 58.9 55.85 1.23 42.8 43.4 43.10 91.8 79.4 61.5 51.25 30—THE IRON AGE, October 26, 1939 tion in. per cent and above while corresponding values for the low- phosphorus steels ran only per cent higher most cases. (3) The resistance atmospheric cor- rosion was materially improved alloy additions phosphorus. Thus found that the end the 3-year exposure period 0.15 0.20 per cent improved the corrosion resistance low-carbon steel about per cent, many low- alloy steels about per cent, and some the most highly alloyed steels about per cent. Another means often used for expressing the rela- tive corrosion resistance between steels compare them for given loss weight. this basis and after years exposure the 0.15 0.20 per cent steels were from two three times more corrosion resistant than low-phosphorus plain-carbon steels, and from 1.2 times more corrosion resistant than low- phosphorus steels the copper-bearing type. extending the test period three years found the additional bene- fit phosphorus decelerating corro- sion rate about one-quarter that plain steel. These effects phosphor- the corrosion resistance steels have been observed others. The only adverse data have seen the effect phosphorus the atmospheric corro- sion resisting properties steels were given Jones” his paper before the Iron and Steel Institute (British) 1937. Jones concluded, after exposing series phosphorus steels the atmos- phere for period orly days, that there was evidence indicate that high-pkosphorus content confers any use- ful increase the resistance corrosion. number discussers his paper pointed out, such short exposure rarely gives more than indication the effect composition changes and certainly value comparing the relative corro- sion resistance different low alloyed steels. tabulation mechanical and cor- rosion test results some the more ors 4 = interesting phosphorus steels given Table The mechanical tests the bar stock were generally more favorable but thought that there will more interest the sheet tests. These results show that there was readily obtained yield strengths over 50,000 Ib. per sq. in., with good ductil- ity and Charpy values. This true all cases for the normalized air- the tensile and yield strengths, and the yield ratio, exert its own specific effects various engineering require- ments as, for example, the ability the steels welded and fabricated. Yet for phosphorus take its place with other alloying elements the compounding steels there still much work done phosphorus steels regards their production, Hoff, “The Development High Strength Steels for Large Steel Struc- tures,” Mitteilungen der Kohle—und 1938, pp. 82. Dawes, “Further Development Weather-Resisting Steels,” Archiv fur das Vol. July, 1935, pp. 45. *S. Epstein, Nead and Halley, “Choosing Composition for Composition, Per Cent Series Others TABLE Tests Phosphorus Alloy Steel Sheets Normalized 22-Gage Sheet Key-Hole Charpy Corrosion Data Tensile Yield Elonga- Strength, Strength, Norm- Loss wt. mg. per sq. cm. 100. Corrodibility index Corrosion Loss, An- 3-Yr. Av. Corro- nealed dibility Sq. In. Ft.—Lb. Sq.Cm. Index* Type Loss wt. mg. per sq. cm. for 0.006 per cent ingot from iron Series cooled condition. Several the steels were found notch brittle the annealed condition, has been com- mented upon others, but several elements were found behavior, particularly chromium, nickel, molybdenum, the other hand, only the an- nealed condition that manifested this type brittleness with the amounts phosphorus used. The information presented this paper adds the knowledge the element. Phosphorus now appears alloying element several com- mercial low-alloyed steels, for very good reasons. The industry will doubt- lessly see its application extend many other types steels enhance atmospheric corrosion, their engineering properties and their metallurgy. REFERENCES *C. Lorig and Krause, “Phos- phorus Alloying Element Low Carbon, Low Alloy Steels,” Metals and Alloys, Vol. 1936, pp. 13, 56, 73. Alloying Element Steel,” Metals and Alloys, Vol. 1935, pp. 280 283, 307 310. *V. Kendall and Taylerson, Critical Study the A.S.T.M. Cor- rosion Data Uncoated Commercial Iron and Steel Sheets,” Proc. A.S.T.M., Vol. 29, 1929, part pp. 204 219. Ristow, “On the Effect Phos- phorus the Properties Basic, Un- alloyed Steel,” Mitteilungen der Kohle— und Eisenforschung G.m.b.H., Vol. part 1935, pp. 84. Low-Alloy, High Strength Steel,” Trans. American Institute Mining and Metal- lurgical Engineers, and Steel Divi- sion, Vol. 120, 1936, pp. 309 345. Stinnes, “On the Influence Sulphur and Phosphorus Contents the Corrosion Steel,” Dissertation for de- gree Doctor Philosophy, West- falischen Wilhelms Universitat, June 23, 1937, pages. Britton, “Some Properties Commercial Steel Sheets Containing Ad- ditions Copper, Manganese, Chromium, and Phosphorus,” Journal Iron and Steel Institute, Vol. 135, No. 1937, pp. 161 185. Jones, ‘The Effect Phosphor- the Mechanical and Corrosion- Resisting Properties Low-Carbon and Low-Alloy Structural Steels,” Journal Iron and Steel Institute, Vol. 135, No. 1937, pp. 113 160. THE IRON AGE, October 26, =: _ 4 re, 4 7 AST week the author re- viewed the various types stainless alloys, the range commercial finishes, types grits, preparation wheels, etc. Herein, the second section two-part article, detailed data are given for polishing various finishes; also, etching and faces. should light possible, and never greater than required cut efficiently. The time required produce given finish will not shortened attempting force oper- ation through increased pressure. For, overheat the surface and result spoiled finishes and buckling. The lat- ter particularly true austenitic steels light gages are mishandled. all polishing operations pressure Nor are attempts shorten opera- tions omitting intermediate steps likely more successful. Fine abrasives and buffing compounds will not remove metal, nor cut the bot- tom scratches cuts remaining from coarse abrasives. Unless these are removed steps with suitable in- termediate abrasives they will always remain and spoil what might other- wise have been attractive finish. 32—THE IRON AGE, October 26, 1939 ° ° ° WALTER MITCHELL beginning polishing operations No. finish, its equivalent, the first step “roughing.” For this, No. abrasive dry glued wheel should used. the surface very rough and uneven, coarse grit, such No. may even necessary. All imperfections the original surface, those that may have opened up, must completely removed operation. sufficiently coarse grit “make bottom” should used, but grit coarser than necessary should avoided deep scratches take much time smooth out. The purpose finish may built up. Failure pro- duce this ground this stage the operation will result much waste time later The No. should followed with No. 100, dry. All and lines produced roughing must removed this second operation. While finer abrasives may used dry after the No. 100, best proceed with Turkish emery (or aluminum-oxide) suitable wheel and apply lubri- cant the surface being polished. good succession will No. 120, No. 150, No. 180, No. No. 220 Turkish emery with grease. For more brilliant finish, operations may carried through with abrasives higher numbers to, and including No. 440 with grease. This will pro- duce very attractive finish, almost mirror Sheets strip with cold rolled finish (No. No. 2D), articles formed from these that have not been annealed pickled, will rarely abrasives unless marked tools dies, and greasing may proceed once using No, 120 Turkish emery. Wheels for the finer abrasives are made sewed sections, bonded to- gether, but with greater cushion than wheels used dry for roughing. Finer count, 80/92, 84/92, unbleached muslin generally used, and the in- sertion cardboard disks, worn down sections, spacers some- times advisable prevent overheating. Where wheels have cleaning accomplished holding lump pumice against the rotating wheel until thoroughly cleaned abrasive can then applied, necessary. the commercial No. finish desired, all surface defects must removed roughing operations and the surface finished uniform ground with No. 100 grit dry. Following this, No. 120 with grease used. some cases match existing No. fin- No. 150 with grease. produce the No. finish, No. 120 followed with Nos. 180, 220, 240, 320, and 400. This finish, pro- duced commercially different mills, will vary considerably. not neces- sar des thr bet spe int tak pri pat ° ° ] nit JS "C fe ° ° pl tl nh d scratch free, but has very much reflective power than the No. final buffing follow polishing true mirror finish (No. desired, operations should carried through Nos. 240 280 with grease buffing compounds are used. For fine polished and satin finishes special abrasive mixtures, known com- mercially “greaseless (Lea compounds), are now coming into use for stainless steels. These take the place the finer abra- sives set-up wheels used with lu- They are mixtures various grades abrasive and glue with non-drying ingredient, and for the market stick form. Thev have the advantage being ap- polishing wheel. directly the rotating wheel and produce flexible, dry surface. Since they not require glue, cement, drying time, they are very convenient, and their use will frequently lower finish- ing costs. They contain grease, required, and cleaning pol- articles much simplified. Wheel speeds for polishing should range between 6000 and 8000 linear it. per min. (about 1600 2100 r.p.m. 14-in. wheel), the higher speed being used with the finer abrasives. With “greaseless compounds” some- what lower speeds are recommended. These suggestions are con- general only. previously hard and fast rules that will ipply every case cannot given, and experimentation with various suc- abrasives will frequently necessary develop the most eco- nomical procedure for particular job. Tampico and Satin Finishes Finishes this type are highly desirable for many kinds work and can produced considerably less cost than the brilliant mirror finishes, which require the expenditure much time and labor. With the ex- tensive variety abrasive available, the character the final finish can modified meet practically any requirement, from coarse dull ap- pearance bright satin finish, sim- ilar that found high grade sil- verware. Satin finishes have the advantage blending with die marks and other minor impertections, removal not important when buffing for mirror finish. Never- theless, for best results all conspic- uous defects must removed, methods already given, and finishing operations carried through No. 120 grit with lubricant. That is, the sur- face should have least No. fin- ish before satin finishing begun. The commercial No. finish (tam- pico brushed) produced brush- ing the surface with rotating brush tampico fiber, bristle, loaded with “emery (about No. 180 grit) and light oil. some cases pumice and kerosene are used. few passes are usually all that are required, the operation consuming few minutes only. The “greaseless are used with excellent results ducing various satin finishes hol- low-ware, novelties, other articles. These are used soft muslin buffs surface speeds 5000 6000 linear ft. per min. Obviously, whatever method used producing the finish, the lines tampico, satin, finishes should run the same direction the original rolling the material, or, the case small articles, the same direction the previous polishing operation. tampico brushing large surfaces, such may used architectural work, necessary that polishing equipment designed that the brush, wheel, can travel the full length the work one stroke. necessary stop and start again brush marks will remain and spoil the appearance the work. Buffing Abrasives and Wheels The purpose buffing pro- duce true mirror finish, entirely free from polishing lines, scratches. This can accomplished less steels the use special abra- sive buffing compounds prepared for the purpose only. contrast polishing, the abrasive not glued, cemented, the wheel, but ap- plied the revolving buff the form compound the abrasive with (lubricant). compounds called “rouges,” which, for stainless steels misnomer since they con- tain iron whatever, and are com- pounds levigated alumina chromic oxide usually resolves itself into THE IRON AGE, October 26, 1939—33 ; two operations: “cutting down” and “coloring,” for which separate abra- sives are required. For cutting down sharper compound used which reduces the rough surface smoother one, preparatory color- ing. Coloring done with milder abrasive, frequently green chromic oxide, which produces quality finish. The abrasive cake stick form applied directly the face the rotating wheel. attempt shorten the time required pressure. may burn the surface and ruin careful preliminary work. Pressure buffing plays very minor part, the cutting action depending almost entirely the sup- ply abrasive and the velocity the wheel. Buffing can easily develop into costly and time consuming operation, especially the final steps produc- ing scratch free, mirror Much the time and cost buffing can avoided intelligent and careful procedure the prelim- inary grinding and polishing, particu- larly the avoidance anything that might produce deep scratches and overheating. Raw material for buffing, whether sheets strip, must highest qual- ity, without deep seams imperfec- tions, the slightest defects remain conspicuously visible and ruin otherwise good finish. not rec- ommended that buffing attempted over ground coarser than No. 240 No. 280 with lubricant. Success buffing depends also the use the proper type wheel. Buffs are usually made from high count 84/92 bleached muslin, linen. For the first, cutting down, opera- tion, the sections may sewed for one two rows around the arbor hole. For the second operation, color buff, unsewed sections are pre- ferred. The wheel should quite loose and soft, but will become suffi- ciently hard when rotating high speed. Ventilation, cooling effect, secured inserting spacers cardboard, worn down sections. There are now special buffs the market (Airway venti- lated buffs) which with rigid center disks metal. Long strips 84/92 unbleached sheeting are used, one side which gath- ered and fastened the central disk. this way the cloth, which gathered tightly the center flares the circumference and forms series folds, pockets. the 34—THE IRON AGE, October 26, 1939 (a) (6) (c) rotates the centrifugal force draws air the center and forces out radially between the sections, thus giving true ventilation. Buffing wheels are used high ve- locities—about 9000 10,000 linear ft. per min. (2500 2800 for 14-in. wheel). Higher speeds are permissible, but must used with great care burning very likely occur. Sheets and Plates Although the plant will usually purchase large sheets plates already polished from the mill and have little occasion for attempting work this character, short description the methods used will not out place. polishing large surfaces, such sheets plates, machines carrying rotating belts charged with abrasive are now generally used. The belts are made paper for narrow widths, and cloth, canvas, for wider widths where greater strength required, There are several arrangements helts and pulleys, shown schematically the accompanying illustration. Ma- chines types (a) and (b) operate somewhat similarly the ordinary machine shop planer; that is, the sheet, plate, clamped flat table which moves back and forth un- ° ° ° types chines for polishing sheets plates and the work moves under the roll, and (c) the work ary while the belt passes Close the sur- face and contact made pressing the belt down with block. der the roll, pulley, around which the belt travels. The roll, which forces the moving belt into contact with the sheet, made sewed buffs provide the cushion effect required. machines types (c) the work stationary while the belt Contact made pressing the mov- ing belt down the surface the sheet with cloth covered cork block. varying the width the belt, small block, this machine conve- niently adapted for “hand spotting” remove pits and other fections. Any the belt machines may used dry, with lubricant. some types, most conveniently with type (c), water cooled bed can pro- vided prevent overheating and burning. Prepared belts alre