The Iron Age 1939-11-23: Vol 144 Iss 21

FRITZ FRANK President J. H. VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Rditor Art Bdétor Metallurgical Rdttor Associate Editors Washington Editor Resident District Editors Pitteburgh Chicago Cleveland Detroit Editorial Correspondents Londen, England Cincinnati FRAZAR Boston Hamburg, Germany San Francisco SANDERSON ROUNTREE, JR. Toronte, Ontarie Birmingham Newark, N. J. St. Louts Buffalo CHILTON COMPANY Copper, for Electricity, Industry and Decoration (Incorporated) ° Publication Office Executive Offices Ohestnut and 56th Sts.. 239 West 39th St. OFFICERS AND DIRECTORS Granite City Expands Capacity FRITZ FRANK, Executive Vice-President What's New Plant Service Equipment? FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, Vice-President EVERIT TERHUNE, Vice-President WILLIAM BARBER, Treasurer Washington News JOHN BLAIR MOFFETT, JOHN VAN DEVENTER, JULIAN CHASE, THOMAS KANE, CHARLES BAUR, THE NEWS BRIEF Statistics Metal Working Activity Weekly Ingot Operating Rates . . BAUR, General Advertising Manager Rate Activity Capital Goods DIX, Manager Reader Service Plant and Equipment Buying 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- ; Single copy 25 cents, Annual Number e $1.00. New Industrial Literature Cable Adéress, ‘‘Ironage, ADVBRTISING STAFF Products Advertised 120 Herman, Chilton Phila. Just Between Two H. K. Hottenstein, 1012 Otis Bidg.. Chicago H. E. Leonard, 289 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit 146 obinson D. C. Warren, P. 0. Box 81. Hartford, Conn. 1595 Pacific Avenue, Long Copyright 1939 by Chilton Company (Ine.) A. * ul, ah 7 Immediate Shipment Assured The ability deliver promptly is, course, outstanding impor- tance today, but Ryerson offers still more. The buyer who may need angles, sheets, bars, welding rod, and many other items assured uniform high quality regardless the size his order. Under the Ryerson Certified Steel Plan, stocks include only selected products that meet the most demanding specifications. The purchaser can then concentrate orders for practically all his steel requirements, securing uniform high quality and quick service saving time and money. Ryerson certified alloy steels are outstanding example the care used the selection our stocks. assure uniformity, entire heats (100 150 tons) alloy that meets our narrow range specifications are secured. Bars are analyzed and tested for chemical and physical properties and heat treatment response. Every bar clearly identified with the heat number. Data sheets and charts showing properties the steel and results the tests are prepared and sent with every order, large small, guide heat treatment. This valuable service given extra cost. Ten large Ryerson plants carrying more than 10,000 kinds, shapes, and sizes steel products stand ready meet both your regular and emergency requirements. you not have the current Ryerson Stock List, shall glad send copy. Joseph Ryerson Son, Inc. Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. 28—THE IRON AGE, November 23, 1939 | ‘ 4 > § 5 a & | iy THE IRON AGE ... NOVEMBER 23, 1939 ESTABLISHED Vol. 144, No. Will Grandpa’s Rejuvenation Last? NCE upon time there was old gentleman who had time his hands. Time enough them enable him good job thinking about his infirmities. thought and thought about them until, his mind, became possessed most the ills listed Doctor Almanac. His legs bothered him, his back ached, heard buzzing sounds his ears and suffered from indigestion and palpitation the heart. One day was tottering down the sunny side the street, taking his constitu- tional, grandpa happened find himself right the scene gangster fight the moment that hostilities began. Bullets flew every direction, some them coming too close the old gentleman comfortable. Dropping his cane and eyeglasses, departed from the scene conflict with all the celerity and agility flaming youth. Some observers say that made the yards the nearest corner ten seconds flat! The excitement seemed grandpa lot good. For some time after the event had new lease life, forgot his pains and aches and went back business. The record does not reveal whether grandpa's rejuvenation was temporary, lasted the rest his life. Personally, believe that was temporary; that time the stimulation wore off and the aches and pains returned. would think that lasting cure would have based something more fundamental than the shock excite- ment, unless his troubles were all imaginary, which was unlikely one his age. think this story grandpa, sometimes, connection with the sudden stimula- tion that has been given American business because the war abroad. Here American business, which has been halting and hobbling along, full aches and pains for seven eight years, suddenly doing the hundred yards ten seconds flat the sound gunfire. Can that this sort performance will lead sound and enduring recovery? Insofar our troubles were imaginary, they can removed, perhaps, diverting our minds from them. But unemployment not imaginary, forty billion National debt not imaginary, pyramiding taxes are not imaginary, the farm problem not imaginary and attempts change from constitutional democracy regimented dictator- ship are not imaginary. You can't laugh them off declaring armistice past mistakes and present Unless, while the patient feeling well, operate some these chronic con- tinuing troubles, they may return plague after the shooting over. ; q = Ty 4 Parts Manufacturer Saves 25% ... with Inland Ledloy Forgings YOU, TOO, can cut costs when you switch Inland Ledloy. When this manufacturer changed from re-sulphur- ized steel Inland Ledloy forgings these parts, production went from pieces per hour— increase 25%. This interesting comment comes from the user: “In addition the increased production, due increased cutting speed Ledloy, are also saving considerable money tool sharp- ening, because the tools last much longer Dearborn St., CHICAGO District Offices: MILWAUKEE STRIP TIN PLATE BARS PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES between grinds the higher cutting speed Ledloy than they formerly lasted lower cutting speed with re-sulphurized you are the alert for ways cut unit manufac- turing costs, you should investigate Inland Ledloy. For Ledloy offers worthwhile economies faster machining and longer tool life. This free-cutting steel retains all the physical characteristics open hearth steel each S.A.E. analysis, except for slight reduc- tion grain size. For further information let send you the new bulletin Inland Ledloy (No. 50). REINFORCING BARS | n M > or W DETROIT ST. PAUL ST. LOUIS ST. PAUL ST. LOUIS SAS CITY CINCINNATI | Business ° FELIX BEYER EDITOR'S Beyer, the German economist who wrote Coming Collapse German for the Oct. issue THE IRON AGE, this week describes some the troubles the business man Hitler Germany which, says, still has capitalist system, sort. Mr. Beyer, who not political refugee, presents his picture political control German industry without attempting draw parallel with the situation facing business men the United States. ° ERMANY has capitalis- tic system sort, and the outbreak the war its business men were struggling preserve what remained this system against the overwhelming pressure dictator- ship. With each step forward, however, the German business man found him- self pushed back two steps gov- greater control the means pro- vaguely remembered that National Socialism was once consid- ered cure for social disease called Communism and with some misgivings, that the Hitler government has decided, dealing the Soviets, that for the first time history the cure and the disease were going try live the same bottle. Still, however, the political leaders the Nazi regime have paid lip ser- vice the system private enter- prise, publicly praising such leaders German industry Krupp von Bohlen und Halbach, Thyssen, Bosch and the late Emil Kirdorff. Such men these have been appointed high govern- ment offices where they gave the re- gime impressive front economic stability. Back this front there is, for American industry, interesting picture. Room for Newcomers you want establish business Germany the chances are hundred one that you would find such move impossible even you have sufficient capital. With few exceptions every branch industry commerce closed newcomers. There exists for tungsverbot (establishment tion) which coupled with prohi- bition enlarge existing firm. Permission establish new firm enlarge old one granted only this “in the national interest” what often the same thing, Na- tional Socialist Party official high- ranking member stands profit establishment the new firm. the man who wishes estab- lish grocery store shoe repair shop has his difficulties. The “Retail Law” and “Handicraft Code” provide that food store proprietor cob- bler must have sufficient professional able, evidence which must shown before examination committee. These examinations have become in- struments monopoly for the Nazis. Many thousands small retail shops and businesses have been put out business and the owners advised seek work government projects THE IRON AGE, November 23, ° ° : > ” 7 | their independent existence aid the Nazi war machine, and the war industries need skilled workers. Lack Trained Men Such suppression free compe- tition has led rapid depletion the number capable executives and busi- ness leaders. Party nepotism gen- eral. Nazi party member, with in- fluence, lives paradise with other party members who “have the golden key” and who form the class which has benefited most from the Hitleriza- tion Germany. Certain party members and high of- ficials have increased their fortunes manifold out the anti-Jewish mea- sures which deprived Jewish owners their enterprises. One the most elegant department stores Germany was acquired minor official municipal chamber commerce (chambers commerce have semi- governmental status the Reich). This official, who had influence the party and believed himself entitled spoils, did not purchase the department store with his own funds. borrowed money from the Labor Front, which the Government Labor organization which collects dues from all German workers. With this money bought some real estate which knew could sell the Army great profit. With his profits bought the depart- ment store. Similarly, banker re- cently acquired textile factory and plant. Clerks with other qualification than influence the party took over the plant their employers with the aid Labor Front bank loan. The Labor Front has, however, also gone into business its own and among other enterprises owns chain restaurants including the “Kempinski.” Politicians Become Owners XPROPRIATION Germany has not been limited Jewish firms. Many profitable firms have run afoul government regula- tions, have been taken away from their owners, and now are run govern- ment commissioners who most in- stances are digging themselves into actual ownership. This ticularly large firms Austria and Czechoslovakia. Firms like the Alpine Montanwerke, largest Austrian producer, and Steyr have managing boards with majority Nazi officials and party officers from old Germany. You cannot hire worker without the permission the local employment agency, the district labor governor 32—THE IRON AGE, November 23, 1939 (Trustee Labor), the Labor Front the Army. You cannot fire the worker without permission nor can the poor fellow leave you order get better job. You may have raw materials and nothing but you cannot release your workers. You just continue paying wages. Probably you cannot lay off the workers, even you received permission, because they are skilled workers you will never see them again. Some plants lost per cent their workers the Gov- ernment for fortification (Siegfried line) work. The question labor not alone complicated the question labor supply but the high degree inse- curity the relations between worker and employer. every plant there least one political representative the Labor Front. Besides, there board shop stewards representa- tives the workers. The employer not, the United States and Great faced with definite wage and hour problems. These problems not officially exist the Government reg- ulates both hours and wages. The therefore knows what his workers actually want. Peace When Unions End The abolition trade unionism Germany has not brought labor peace but instead has been supplanted in- trigue. The conference table has made way conspiracy. Sabotage and slow-up strikes have become important weapons the workers. The shop stewards try give the needs the workers legitimate this not easy matter the em- hands are also tied. Here again the state and the party repre- sented the District Labor Governor, the Employment Agency and the La- bor Front are the deal. may pointed out that the Labor mann) plant constitutes particu- lar menace. often sees himself the boss the future and constant- the lookout for lack national socialist enthusiasm the part the employer. political joke told the wrong moment may land the employer the concentration camp and the La- bor Front representative the swivel chair the boss. There are many such cases. However, these Labor Front Repre- sentatives can also the boss’ best friend. may sometimes cost some- thing but, from wholly materialistic viewpoint, worthwhile invest- ment. Very often the employer forced contribute some special fund for alleged violations wage and hour regulations even for having reproved employee. one case employer had promise give each his employees one the cheap small motor cars which are pro- duced the Labor Front sometime 1942 later. This was not profitable for the employer and did not help the workers much but gain for the Labor Front which has staff some hundred thousand tionaries. subscription and paid advertisements Front and Nazi magazines are also highly profitable. Red Tape Like Steel Wire HERE not single action (German business man that not hampered red tape steel-wire like tenacity. Daily must fight for his raw materials. must run down the competent government raw ma- | | | | | | | j | ~ 4 le Pip z= 4 | _£ = — terial control office which there are some and talk bribe the official into granting him least part what due him. Usually plant’s theoretical raw material supply fixed percentage the consumption during previous key year. These percentages are lowered from month month. Furthermore the deliveries raw material depend the impor- tance the order for which they are needed for the national defense pro- gram. However, big firms that can maintain their own lobbies and contact men the raw material control bu- reau, and ministries and firms that have good and sometimes very expen- sive connections, receive preferential treatment. Many minor official such bureau has been able buy comfortable villa and pad other- wise insignificant salary with income. The shortage raw materials has disastrous results from the viewpoint industrial efficiency since lack few kilograms special alloy can halt production large project. is, however, not alone the raw shortage itself which constitutes bur- den the industrialist. With the ad- ministration raw materials con- nected unbelievable volume office work. Steel Figures Every Week Forms must filled out from the Government Control offices that show the consumption every raw material during certain key period which present allotments are based. The periods are different for every raw material. Separate figures must submitted for materials used ex- ported goods. Figures must submit- ted every month and certain cases (iron-steel) every week with regard actual consumption present and the amount needed for future orders. Statistics regarding future deliveries must subdivided into different cate- gories, viz., orders from the army, or- ders from firms working for the army, orders for enterprises working the national interest, orders for orders for the four-year plan, orders from the German railroads, Govern- ment Building projects, etc., etc. Stocks raw materials and fuels (in partic- ular oil and gas) and semi-finished products must reported monthly special forms. Any important changes must reported immediately. hoarding even the keeping slight- above normal stocks permitted and excess stocks must offered the Government. Heavy fines and prison sentences are threatened those who dare disobey the Government’s raw material regulations not fill out statistical form sheet. There new regulation form sheet nearly every day. Industrial accidents whether important not must reported (CONTINUED PAGE 78) THE IRON AGE, November 23, Tabs: } q 3 ; 4 q j ~ undergone fundamental changes recent years and consequent- the steel industry has spent huge sums money for costly equipment meet these demands. The increas- ing production flat rolled products has led the building number hot and cold strip mills, which have, present, annual capacity ex- cess 15,000,000 gross tons. Further- more, consumer demand for better and more uniform physical properties, par- ticularly deep drawing qualities, have necessitated exacting control during the hot and cold finishing manufactur- ing operations. The motor car industry, the largest steel consuming group, form quality and large sheets having extra deep drawing properties. These large sheets, necessitated the produc- tion all-steel bodies and tops, re- quire the use larger ingots than were formerly standard sheet pro- duction. And, turn, the more pro- nounced segregation metalloids these larger ingots adds the difficul- maintaining uniformity prod- uct. Rimmed Steel Desirable Practically all the sheet used for deep drawing rimming steel. The *Professor metallurgy and instructor metallurgy respectively University Minnesota. 34—THE IRON AGE, November 23, 1939 ° PEN HEARTH ° ° ° LTHOUGH the general effect non-metallic inclusions the physical properties steels has been frequently discussed, little the way quantitative work the specific effects these inclusions has been reported. This article makes comprehensive contribution along this line. this, ihe first section three-part article, data are given regarding the inclusions found slabs and rejected sheets. surface the sheet comes rim the ingot. This rim pure metal produced the evolution ‘gas which cleanses the surfaces growing crystals during the solidifica- tion the ingot. Because clean and relatively low metalloids, the rim very ductile and capable tak- ing high finish the cold strip mill. However, surrounds zone high metalloids, due segregation from the rim. This zone liquidation greater the top-center the ingot than any other position, which point the carbon, manganese, phos- phorus, and sulphur are present the maximum amounts, causing the sheet least ductile. Because this segregation, the top portion (nearly one-third) each ingot must either remelted applied orders having practice, however, adds the cost manufacture. all the metalloids, the segrega- tion sulphur perhaps the most marked and may have very detrimental effects. Sulphur segregates the sul- phides iron and manganese and may produce long stringers inclusions rolled steel. While mostly manganese sulphide, these non-metallic inclusions also contain certain amounts iron and manganese oxides, and are often associated with silica and alumina. Such steel microscopically dirty, has poor drawing properties due the often said laminated. Much has been written regarding the general effect non-metallic in- clusions the physical properties steel. However, little quantitative work has been reported regarding the spe- cific effects these view the limited information the effect and composition these non- number studies were made. Two these will described: First, quan- titative identification the non-metal- lic slab and second, the 7 | i | _| a Vv R ‘ TABLE Quantitative Identification Non-Metallic Inclusions Slab Strip Mill Steel SKIN SAMPLE Average Test No. Per Cent 0.0000 0.0044 0.0029 0.0024 0.0088 0.0113 0.0080 0.0094 FeO 0.0473 0.0262 0.0359 MnO 0.0027 0.0033 0.0024 0.0027 FeS 0.0200 0.0385 0.0293 MnS 0.0112 0.0056 0.0084 Total average non-metallic inclusions (Per Cent) Oxide sulphide ratio 1.337. JUNCTURE SAMPLE Average 0.0013 0.0010 0.0020 0.0033 0.0000 0.0017 0.0048 0.0044 0.0045 0.0045 0.0038 0.0044 FeO 0.0203 0.0272 0.0210 0.0196 0.0558 0.0288 MnO 0.0033 0.0043 0.0038 0.0014 0.0067 0.0039 FeS 0.0577 0.0192 0.0385 0.0385 MnS 0.0248 0.0372 0.0352 0.0324 Total average non-metallic inclusions (Per Cent) 0.1097. Oxide sulphide ratio —0.547. CENTER SAMPLE Average 0.0004 0.0008 0.0017 0.0046 0.0039 0.0023 0.0030 0.0032 0.0034 0.0055 0.0013 0.0035 FeO 0.0483 0.0154 0.0476 0.0470 0.0471 0.0411 MnO 0.0022 0.0036 0.0026 0.0030 0.0013 0.0026 FeS 0.0385 0.0659 0.0797 0.0577 0.0687 MnS 0.0179 0.0136 0.0108 0.0275 0.0105 Total average non-metallic inclusions (Per Cent) 0.1277. Oxide sulphide ratio 0.633. Not determined. TABLE OXIDE ANALYSIS STEEL SHEET REJECTED BECAUSE LAMINATIONS Sample No. Sample No. (Per Cent) (Per Cent) 0.0130 0.0042 0.0284 0.0150 FeO 0.040! 0.0117 MnO 0.0414 0.0118 Total oxides 0.1229 per cent quantitative determination the non- metallic inclusions two samples steel sheet rejected consumer. Structure Rimmed Ingot The structure ingot rimmed steel shown Fig. The cross- section in. ingot was ob- tained splitting plane through the center line and parallel the 24- in. side. Holes which the dynamite was placed appear the upper part the figure. ingot rimming Marshall, Jr., and “The De- velopment Electrolytic Method for the Determination Inclusions Plain- 0.0427 per cent steel may seen consist four distinct zones follows: (1) very thin skin (A) quick- chilled steel approximately the same composition the ladle test. (2) Adjacent this skin the rim zone (A-B) high purity steel which may contain pencil-like blowholes nor- mal the ingot surface. These are usually called primary blowholes be- cause they are first form during solidification the ingot. (3) narrow zone (B-C) com- paratively impure material associated with blowholes globular form, called secondary intermediate holes. This zone particular interest many steel failures occur this point, due laminations. (4) The central portion (C-E) the core consists material less pure and less uniform composition. this zone maximum segregation the most impure metal the top. Globu- lar blowholes, known central holes, are scattered throughout this area. Inclusions Slab The positions the samples that were taken from strip mill slab for oxide and sulphide determinations are shown diagrammatically Fig. short cross-section the slab from the center ingot was sheared off, machined, and etched observe the macro-structure. From the etched surface, zones and were located. Zone was identified narrow line, and had been the secondary blow- hole zone, was the juncture zones and Zone was not determinable but zone with very dense structure uniformly etched extended the sur- face. Being the center the slab, the position zone was easily deter- mined. was deeply etched. Sec- tions about in. thick were cut from the three zones indicated Fig. For identification they were labeled “skin” for zone “juncture” for zone and “center” for zone The ap- pearance these longitudinal sections after etching shown Fig. The distortion was due the shear drag during the cutting the slabbing mill. These longitudinal sections were further cut, shown Fig. into pieces suitable for oxide and sulphide analysis. Each piece was analyzed separately. oxide analysis was made according the electrolytic io- dine extraction method, and the sul- phides calculated from determination the total sulphur present according the method Fitterer.* While this method may not exact, the re- sults give some indication the dis- tribution sulphides. The oxide and sulphide analyses are given Table The analyses the non-metallic inclusions the strip mill slab show that the patterns developed during deep etching are associated with the high sulphur areas. The included matter, principally iron and manganese sul- phide, was extremely high the junc- ture. Due the fact that the junc- ture narrow line the slab, the sample analyzed contained portion the skin, some the center, and the line greatest segregation. The average sulphide content the junc- ture 0.071 per cent, compared with 0.038 per cent the skin zone, and THE IRON AGE, November 23, 7 7 > 0.080 per cent the center zone. Thus, these average figures juncture thin film extremely impure material, and probably con- ducive steel failures this point. Failures observed the secondary blowhole region could caused the occurrence these holes and impure material the same narrow zone. During the rimming action, the liquid non-metallic material rejected from the skin and forms very impure layer just front the solidifying metal. The capping the ingot, any outside change conditions, may alter the solidifying process trapping these inclusions and gases. The gases form blowholes into which the liquid forced, and the presence these im- purities these blowholes may first 36—THE IRON AGE, November 23, 1939 IG. Cross section struc- ture rimmed ingot. Numbers and letters refer sampling positions for sulphur analyses. Core 2—Diagrammatic sketch showing positions samples for oxide and sulphide analyses slab. ° ° ° BELOW IG. 3—Sections strip mill slab, deep etched, showing positions samples used for non-metallic inclusion analyses. ¥ & CENTER cause poor welding during the subse- quent rolling. Furthermore, weak spot thus produced may cause failure during the forming operations the finished product. Inclusions Rejected Sheets The conditions just sulted the rejection number steel sheets due non-metallic inclu- sions occurring stringers. Samples from two such rejected sheets were examined for inclusions. The results are shown Figs. inclusive. Figs. and taken random from sample No. represent the aver- age condition the sheet. Figs. and represent sample No. Both samples are carbon strip mill sheet 0.045 in. thick. The oxide analyses the two samples are given Table II. { | > q 7 £65 Metallographic methods inclusion identification stringers contained phide compounds. sions with well defined edges occur here and there the stringers, and these presumably are some the ox- ides. Sample No. contains extraordi- nary amounts oxides, while sample No, nearly normal. Sample No. was, however, also defective. The heavy segregate was clearly defined the position the secondary blowhole zone sample No. Although less clearly defined, was similarly located sample No. Sample No. appears have come from position nearer the bottom the ingot. When such stringers occur, the ductility and qual- ity the steel are lowered. The continuity the inclusion influenced its softening and melting points. high sulphur creases the tendency for the inclusions form stringers, because the low melting point the oxy-sulphide ma- terial. Ed. Note: Next week the authors con- tinue with information the effect sulphur grain size and physical prop- erties strip steel, and sources sul- phur the basic open hearth. LEFT IGS. (top), (center), and (bottom)—Photomicrographs showing typical inclusions, size, shape, and distribution sheet steel, sample No. The con- are the secondary blow-hole zone. RIGHT showing typical inclusions, size, shape and distribution sheet steel, sample No. con- are the secondary blow-hole zone. | | re #3 | | % » - pom . s INTH series ar- ticles dealing with Right Metal the Right designed aid manufacturers selecting the most suitable non-ferrous metal alloy for their prod- ucts probably the best known, the most widely used, the largest tonnage metal, the metal with which the man the street well the woman the home are most familiar, copper. The original metal an- tiquity, was probabiy first used for weapons and defensive armor. Today, sable material civilization. the outstanding metal the electrical industries. But even though the electrical in- dustries are far and away the largest users, copper has its long history infiltrated throughout all metal prod- ucts manufacturing degree per- haps unequalled any other metal. result, the variety its uses, the multitude its forms and the number its alloys has created condition which may well leave the prospective user bewildered when attempts make choice. Basic Properties Copper red metal only mod- erate strength and hardness but very malleable and ductile. Cold working rolling, forging, etc., increases its tensile strength and hardness. Where considerable strength and toughness are required, they must obtained the addition other metals, with without heat treatment. The extensive use copper for electrical purposes rests upon its high electrical conductivity. Only one metal stands above this respect—silver with rating about 105 against Manual for Non-Ferrous Metals, Sam Tour, 1938. 38—THE IRON AGE, November 23, 1939 ad 100 for copper. All other commercial metals are lower. Copper also ranks next silver heat conductivity. Copper withstands many forms corrosion. Historic evidence exists ‘in copper implements pre-historic origin, found archaeologists. At- mospheric corrosion results skin basic sulphate which does not ab- sorb moisture and which resists further atmospheric attack. The protective corrosion product commonly known “patina,” the familiar green coating. Such coat can today formed artificial means for decorative and utility purposes. Copper and its alloys have rela- tively good resistance number dilute acids, for example, acetic acid (in the absence air), and number other organic acids, sulphur dioxide and sulphite solutions used pulp mills, the alkalies, potassium and sodium hydroxide, and variety salts. resistant domestic water, industrial and brine waters, and sea water. Copper has always been the leader for Pressure die the trend toward high purity. Com- mercial copper, although produced several grades suitable for variety purposes, best known industry the form electrolytic and “tough pitch” copper, over 99.9 per cent pure (silver being counted copper) the balance being oxygen other minor impurities. even higher purity product deoxidized oxygen-free copper, comparatively recent This grade practically inert the action hydrogen and other reducing gases. also seems give superior service under repeated stress. may used advantage for welded and brazed parts, and for parts subjected difficult forming and spinning oper- ations, because its higher ductility. Another important form copper, fire refined metal, 99.9 per cent pure, which contains arsenic and silver. These are natural impurities the metal produced Michigan and have adverse effects except that arsenic reduces the electrical con- Arsenical copper used requires ductivity. where the work greater | 4 e | A g | a’. 4 4 pe 01 Cl pe toughness and wear resistance, for ex- ample, locomotive fire boxes and stay bolt bars. Arsenic from 0.25 0.50 per cent raises the annealing tem- perature the copper deg. and 0.1 per cent silver raises over 180 deg. F., thus retarding softening high temperature service. Casting copper, running about 99.5 per cent, made generally ondary metal, used for variety copper and copper-base alloy castings. One our oldest industrial falla- cies the “hardened” copper theory. Time and again such “revolution- ary” development has been presented —the production hardened “tem- pered” copper, lost art “rediscov- Although this ghost has been laid many times, discussion complete without driving another nail into its coffin. There are only two ways hardening copper. One cold work, which changes properties already noted; the other the addition (intentional unintentional) other metals, which case longer copper but These additions, uncontrolled and many cases unknown proportions, and often accidental, may produce material brittle useless for practical purposes. There are today, however, alloys copper with small amounts other metals which are not only hard but tough, whose prop- erties are controllable and changeable will within certain limits, heat treatment. These copper base mix- tures constitute important modern development copper alloys, but they are not hardened copper; they are heat treatable copper alloys. Nomenclature Together with the great number copper base alloys has come perfect swarm trade names. may almost said that for every mixture con- taining copper, there special trade name. So, very commonly heard question industry is, “Have you heard Blankilite? Where can get And all too seldom can one give the answer since Blankilite may here today and gone tomorrow, and best only one hundreds specially named products. Another, and less innocuous complication the fact that many mixtures have been called “bronzes” “silvers” regardless their actual constituents. late, the Federal Trade Commission has taken steps eliminate misleading trade names where precious metals are Alloys Copper Copper alloys may grouped into classes based their main alloying constituents. alloys are copper-tin alloys are bronzes; copper-nickel alloys are cupro-nickels, and on. However, considering the copper alloys containing two more other metals varying amounts, many complications are encountered such those which have made nomen- clature such problem. For example, mixtures are gen- erally known nickel-silver (origi- nally German silver) but are really nickel-brasses. Tour* has made important con- tribution his suggestion that the term “brass” confined copper- ADOLPH BREGMAN Consulting Engineer, New York zine alloys, and the term applicable copper-base alloys con- taining alloying elements other than zinc, and sufficient amounts predominant over zinc their effect the properties the mixture. The best standard list copper base casting mixtures may found A.S.T.M. Specifications B-30-36, entitled Standard Specifications for Copper Base Alloys Ingot Form for Sand Castings, which lists mix- tures bronzes, red brasses, semi-red brasses, yellow brasses and high lead alloys, including appendix giving their physical properties and examples their uses. These few combinations may well accepted cover ad- equately, almost all the uses claimed for several hundred alloys under vari- ous and assorted trade names. Their constituents are principally copper with tin, lead and zinc, with very small amounts antimony, iron, nickel and silicon. Their tensile strengths range from 22,000 40,000 Ib. per sq. in.; their elongations, from down per cent; their Brinell hard- nesses, from 65. Their uses include valves, bearings, automobile fittings, plumbing fixtures, ornamental and architectural castings. outstanding special casting alloy the “manganese bronze” (really manganese brass), composed 55-60 3.5 manganese, 1.5 aluminum and per cent iron. This sometimes called brass, for its very high strength, 70,000 Ib. per sq. in. recent years, nickel has assumed considerable importance constit- uent, with much per cent used for improving the casting prop- copper-base alloys and also factor precipitation hardening heat treatable alloys. Castings for electrical work conductivity” copper castings) most often contain chromium, beryllium, cadmium, nickel cobalt. The wrought brasses range com- THE IRON AGE, November 23, a . x alloys. 1s 7 nt. nd i “4 ike . Ie ept = sed { bie copper-42 zinc. Their color varies from red yellow the copper decreased per cent. Below and especially around per cent the color again becomes more golden red. are obtainable sheet, rod, wire, tube and forging stock, various tempers, from soft (annealed) spring temper. Tensile strengths run from 32,000 per sq. in. about 90,000 elongations from down per cent. The high-copper alloys (rich low brasses) are the most mal- leable and ductile ordinary temper- atures. The low-copper alloys (high brasses) have high tensile strengths and can worked hot well cold. some these alloys, generally those ranging from copper, lead added amounts varying from about per cent facilitate machining. some cases tin, from corrosion resistance. Typical uses, picked out the enormous number individual applications, are the follow- ing: Gilding metal—95 copper, zinc —for inexpensive jewelry commercial bronze—90 copper, zinc—for hard- ware and window screening; rich low copper, zinc—for novel- ties and brass pipe; low brass—80 copper, zinc, for architectural and building purposes; admiralty copper, zinc, tin—for condenser tubes; cartridge brass—70 copper, zinc—for cartridge cases and musical instruments; yellow brass—65 copper, zinc—for drawn parts, springs, safety pins, fixtures, etc. (most commonly used brass, known 1”); and Muntz metal—60 copper, zinc—for fresh water condensers and architectural uses modified forms. The bronzes commercial use when cast carry per cent tin (for bells), but when wrought, gen- erally from per cent down. They are best known phosphor bronzes reason the minute quantity phosphorus used the manufacture the alloy. Their chief character- istics are high strength, hardness, resiliency and resistance fatigue, all which make them useful for springs. They are also widely used bridge bearings for heavy duty service. The copper-nickel alloys are another important class. the high copper side, they make strong, tough alloys with good corrosion resistance. With more nickel they have valuable elec- trical properties like thermal electro- motive force against copper iron, and high electrical resistance. Copper with nickel from per cent com- 40—THE IRON AGE, November 23, 1939 petes with arsenical copper for use locomotive fire box stays. copper—5 nickel used for the driv- ing bands projectiles; copper- nickel for bullet jackets; copper —25 nickel for coinage. Cupro-nickel (copper 70, nickel 30) has made corrosion-resistant marine condenser tubing. Copper-zine alloys with per cent nickel have long been stand- ard materials, formerly known nickel silver, tor use silver plated tableware, flatware, keys, plumbing fixtures and architectural hardware. Changes the nickel content give in- teresting variations the colors these alloys which makes them highly suitable for decorative architectural work. The high nickel alloys are typified Constantan, (60 copper, nickel) which used for resistance coils potentiometers and one the wire elements base metal thermocouples for measuring medium and low tem- peratures; and Manganin with copper nickel below used re- sistance coils heating elements. outstanding example high nickel-copper alloy with about nickel, copper and per cent iron, silicon and manganese. This natural alloy with broad. range high strength and corrosion- resistance which really nickel-base alloy, discussed the article this series dealing with nickel. class copper alloys which has steadily gained firmer place for it- the aluminum bronze group, with about copper, per cent aluminum, iron metals. Their outstanding qualities are high strength, toughness and general cor- rosion resistance. They find place cations. this time the trade witnessing important trend, the development high strength and heat treatable copper alloys through the use small quantities additive agents, which erties copper far out proportion the quantities One the most important groups this class are the silicon-bronzes, containing per cent silicon with small addi- tions manganese, zinc, iron and tin. The silicon-bronzes are strong mild steel and have corrosion re- sistance about that copper. For VERDUR electrical speed rail transit line that reason they have become im- portant factor the manufacture service parts sewage disposal plants, chemical and industrial plants, for cor- rosion resistant tubing, pumps, tanks, wire mesh, screws, bolts, rivets and many types fittings. Another important newcomer heat treatable beryllium copper, which con- tains about per cent beryllium, balance mainly copper. has extra- ordinary strength, fatigue limit and hardness, and therefore coming into extensive use for springs. a ‘tp we ‘ Ba anes — 4 owore 7 1 i | 1 tle runway adjoining the high River bridge, from Phila- rosion resistance about the same that copper. Copper-cadmium alloys, containing around per cent cadmium, and copper-chromium (copper plus about 0.9 per cent chromium) have the ad- vantage high strength and abrasion eat resistance and the same time much higher electrical conductivity than generally found alloys copper, making them suitable for electrical conductive purposes where high and resistance wear are required. sketchy review, clear that copper and its alloys are used scores industries and literally for thousands specific applications. How then can the user metals and the manufact- urer metal products know whether not copper will “fit into ture the simplest possible fashion the service for which this metal its al- loys must considered are tivity (the highest any the base metals) puts the first place. The electrical industries, which have recent years consumed about per cent the copper produced this country, include power transmission lines, current distribution apparatus, bus bars, switchboards, generators, motors, electric transportation equip- ment like locomotives, electric appli- ances like radio receiving sets, refrig- erators, irons, toasters, washing ma- chines, etc. word, the product electrical certain use copper one place another. automobiles, copper brass the material for radiators. Heat con- and resistance corrosion water have kept them use for this and similar purposes. Other automobile applications metal and alloy form include carburetor and fittings, bushings, metal trim and accessories. This same resistance corrosion water and air has enabled copper and brass make outstanding records for themselves household water piping, fittings, steam hose, hot water heaters and storage tanks, wire screen- ing, hardware, lighting fixtures, Other building and household uses in- clude plumbing, screening, hardware, lighting fixtures, windows, ditioning and refrigerating apparatus. Its chemical properties have brought copper the fore equipment for the manufacture variety chem- icals: dilute acids, alkalies and salts; distilleries and for gas- oline supply; for textile printing, food plants; paper mills. important use “of elder day” which was almost entirely lost, but which beginning come back, fine kitchen Copper kettles and pots, because their appearance, their long life and their high heat conductivity rank with the best. For industrial purposes, applications copper and its alloys are numer- ous almost unlistable. Typical examples include piping, pump liners, heavy duty bearings, gas, water and air fittings, locomotive parts and car journal bearings. marine work copper alloys are indispensable reason their resistance salt water corrosion. Manufacturing uses im- portance include brazing solders and welding rods. And addition there are literally thousands individual uses novel- ties, moderate low priced jewelry, clocks and watches, musical instru- ments, bedsteads, eyelets, pins, name plates, rivets, picture wire— and almost indefinitely—all based primarily the long life the metal, its ability worked and with- stand abuse. One its important advantages its attractive appearance and ease finishing. Copper and its alloys have the unique faculty being able take readily almost any finish—from plain polish electroplate, lacquer, enamel, chemical colors and fancy art finishes. The very latest example electrolytic process for developing copper most the colors recogniz- able the physical spectrum. Bronze statuary has come down through the ages. The appearance copper, metal alloy form always its tavor. Future Trends Copper fully abreast the times. once the most ancient and the most modern metal. But still has broad future before it. Like many other metals, its development seems proceeding the direction alloys for special and with the growing acquaintance industry with the special, unusual and even the rare metals, this trend would carry for some time. Among the metals now being used with copper are antimony, chromium, cobalt, molybdenum, tung- sten, selenium, tellurium, zirconium, and even lithium, thorium and ura- nium. The welding copper and its alloys, originally difficult operation because its rapid oxidation, high heat con- ductivity and consequently rapid dis- persion the heat, now being done regularly the oxy-acetylene torch and the carbon and metallic arc. Powder metallurgy which has arous- widespread interest has made more progress with copper than with any other metal and bids fair continue developing. bearings using copper powder have been successfully used large numbers automobiles during the last few years. (CONCLUDED PAGE 77) THE IRON AGE, November 23, 3 | | | git | INTH Series Articles the Technical and Economic Aspects Metal Cleaning and Finishing LECTROLYTIC carried out both acid and al- kaline solutions. The latter so- lution usually precedes the acid bath for the purpose removing grease, oil, dirt, practically all types foreign material. For the purpose this article, the acid bath process confined the removal rolling mill scale, heat-treating scale produced the work various heat- ing operations. Obviously, all such scale must removed suitable finish obtained; however, de- scaling many machine parts car- ried out for still more important reason, specifically gears which run oil closed housings. The inter- nal surfaces such housings, and other structural elements must freed all scale for the sake long life the mechanism. general, such parts transmis- sion gears and gears the differen- tial unit, both found the automo- bile, truck and tractor, require descal- ing perform satisfactorily. Prior the widespread adoption descaling, was not uncommon find such parts shedding their scale through use, the result being that wear was in- removing the scale prior as- sembling, life these machine ele- ments has been appreciably increased. Although only few the parts usually given this treatment have been mentioned, there are many thousand other applications; fact, electric de- scaling can applied with resultant increase useful life and appearance every metallic article somewhere along the production line. Descaling has been considered regular operation many manufactur- director, Magnus Chemical 42—THE IRON AGE, November 23, 1939 ing plants for many years. more generally known under the name pickling, which was designed re- move the oxides from the iron sur- face. The application electricity the bath more recent develop- ment and was designed speed the work descaling and limit the action scale removal without effect upon the underlying. metal. such operations are speeded up, resulting lowered labor and equipment stand-by charges, their application becomes more general. This particularly true the electrolytic method, served reduce the time pickling very appreciable extent. Since this has become prominent re- cent years, something should known about the underlying theory. through aqueous solution acid alkali liberates hydrogen gas the cathode and oxygen the anode. The ion plates out point where the underlying metal exposed, forming the nucleus bubble. the bubble expands pries off the dirt. Obviously the liberation hydro- gen the important function, and the condition the bath well the use current determines the speed cleaning considerable extent. has been found experiment that electricity per sq. ft. cathode area and using boiling electrolyte, ap- proximately cu. in. hydrogen are evolved from each square foot surface per minute. This seems the average practice regard the application today. There are certain limitations with regard the concentration the elec- trolyte well the density the current used. For instance, although the conductivity the electrolyte in- creases with increase concentra- tion the point soon reached where further increase concentration valueless and even detrimental. The manufacturer the cleaner should consulted the most efficient con- centration used. One prominent manufacturer specifies that oz. their cleaner per gallon water boiling point and using direct current current density amp. per sq. ft. work surface. Fig. shows the application the electrolytic process with alkaline solution the plant the Mack Mfg. Co., located New Brunswick, This portion the Bullard Dunn Co. equipment fise and consists steel tank having lead lining and capacity 438 gal. The cathode bars are spaced in. apart. Direct cur- used. The solution made oz. alkaline cleaner per gal. water. The work allowed hang the bath for period time from min. The operator seen removing transmission gears from the tank, rins- ing them cold water and placing them the acid bath adjacent. importance the cleaning solu- tion freeness from too great tendency foam. With the usual vigorous gas evolution the elec- trodes solution having tendency foam sud will build foam blanket composed hydrogen and oxygen bubbles forming ex- plosive gas mixture. This gas may ignited spark from the elec- trode, the result being that liquid thrown from the tank. good practice run the work through washing machine prior its being placed the electrolytic cleaner, thereby using the latter for the finish work only. washing the work solvent soap solution first and then rinsing, the saponifiable mate- rial largely removed, which turn avoids the production soluble soap the alkaline solution. Heat almost necessity con- | = ] | | | n a n I v v n 5 t Pp > a p 7 C ° ° ° ° Why and how clean metals electrolytically—the solutions, current and equipment used and type nection with electric cleaning and advisable all cases increase the speed the operation. The usual method heating steam coils immersed the solution and provided with insulated bushing the point where the pipe passes through the tank wall. not advisable con- nect the condensate line from the heater coil the regular vacuum re- turn system view th