The Iron Age 1939-12-28: Vol 144 Iss 26

VAN DEVENTER Editor Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Bditer Washington Editor ~ Editorial Correspondents Resident District Editors Pittsburgh Chicago Cleveland Detroit London, England Cincinnati FRAZAR Boston Hamburg, Germany Milwaukee San Francisco Toronto, Ontario Birmingham Leroy ALLISON Roy EDMONDS Newark, N. J. St. Louis t Buffalo Happy New Year! Owned and Published by CHILTON COMPANY (Incorporated) Cupola Possibilities and High Strength Snow Cruiser Welded Induction Hardening Drill Chuck Bodies Publication Office Executive Offices Chestnut and 56th Sts.. 239 West 39th St.. ° ° Philadelphia, Pa.. York, What's New Machine Tools OFFICERS AND DIRECTORS Cc. A. MUSSELMAN, President New Machine for Cold Straightening 35 JOSEPH 8S. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President the Assembly Line EVERIT Vice-President WILLIAM A. BARBER, Treasurer JOHN BLAIR Secretary Washington News JOHN VAN DEVENTER, JULIAN CHASE, KANE, CHARLES BAUR, 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 in the Industrial Arts Index. : Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; ada, $8.50; Foreign, $12.00 year. Single copy, 25 cents. Annual Num- her $1.00. Cable Products Advertised STAPF Robert 621 Union Bldg., Cleveland Between Two B. L. Herman, Chilton Bldg., Phila. . E. Leonard, é th St., New York . Peirce Lewis. 7310 Woodward Ave., Detroit dvertisers C. Hi. Ober. 239 W. 39th St., New York Index to A Named DBL its discoverer, presaged important place the tool steel in- dustry, even from its very discovery four years ago. Laboratory tests stimulated this enthusiasm. Now, glowing reports from users prove DBL worthy serious con- sideration wherever high speed steel used. shop practice requires extra equipment elaborate process contains less tungsten being lower price definitely tune with the times. DBL merits your serious consideration. Complete shop practice available you certified Data Sheet available for the asking. Allegheny Ludlum periodical narrating late practice and forecasting bit the future. you are not receiving it, write your company stationery. | \ \ \ THE IRON AGE ... DECEMBER 28, ESTABLISHED 1855 Vol. 144, No. Happy New customs have strong hold America, which excellent thing for the preservation Democracy. And one the oldest customs which deeply ingrained humanity that has out- lived even the fallen democracies the habit wishing your neighbors well New Year's Day. this occasion, the last issue The Age appear extend our best wishes for happi- ness and prosperity during 1940 our ever growing family readers and advertisers. appreciate the business, personal corporate, that you have seen fit transact with us, but more than this appreciate and value the friendship which goes far be- yond business transaction and that evident your contacts and correspondence with us. hope that shall continue deserve your friendship and will make that our principal objective for would have liked send each one you per- sonal greeting card, but since that, course, im- possible, please accept this expression our good will and best wishes. you live long and Ex. ; om x ? ¥ 5 4 : SHEETS STRIP ORE FOR THE HEARTHS Butting through cold, gray seas, Inland’s fleet ore boats plied its way this year until ice closed the lakes’ highway. They have laid huge stocks ore In- diana Harbor—an ample winter’s supply for Inland’s battery modern blast furnaces. This typical the manner which In- TIN PLATE GARS PLATES STRUCTURALS LAND land using, capacity, every unit its resource its man power —to satisfy the urgent needs Inland’s customers. Nor mere tonnage enough; Inland products—as always—will meet the same high standards quality that users have learned expect from Inland. PILING RAILS TRACK ACCESSORIES REINFORCING BARS - - 5 aN Dearborn St., CHICAGO District Offices: MILWAUKEE DETROIT ST. PAUL ST. LOUIS KANSAS CITY AND LIMITATIONS Making IRON signs the times indicate that the foundryman will un- der increasing customer pressure supply high-strength, “high- test’ and alloy irons. Or, phraseology not agreed with, per- haps could stated that the foundry- man who can produce high-strength irons has product which can mer- chandise, one that opens field service that cannot entered the foundryman who can but soft gray iron. has been that per cent the total American gray iron output 1937 was alloyed. And might expected that equal amount unalloyed high-strength iron was produced. Every sign, including the hearty reception given the American Association Handbook Alloy Cast Iron, leads the con- clusion that, and very soon, somewhere between one-fourth and one-third the gray iron output will some vari- ety high-strength iron. The atten- tion being given “high additional straw the wind. The foundryman who can only supply the garden varieties iron will find his Stanley, Annual Report, Inter- national Nickel Co. Canada for 1938. Pearce, First Report Research Committee High-Duty Cast Irons for General Engineering Purposes, Institute Mechanical Engineers, Session 1988, Advance Copy. ° ° ° Battelle Memorial Institute authors point out the growing demand for high-strength iron and devote great deal attention the making good base iron, dis- counting the same time the fre- quent efforts the part foundry- men make poor iron into fair one means alloys. great deal data given the new material Fer means permitting the smaller founder economically pro- duce high-strength irons. These data were all originally presented the authors the recent Chicago regional conference the American Foundry- men's Association. sales outlets progressively restricted. time right now for individual foundrymen consider how they can produce high-strength iron definite plans for its production before they wake find their market gone. Most customers who want both com- mon and high-strength irons for dif- ferent purposes will favor ducer who can supply all their casting needs rather than only part them. High-strength iron may defined A.S.T.M. Class iron, e., that shows 40,000 per sq. strength more, with the “or more” going 60,000 and perhaps higher. the production high-strength cast iron, any other product, the cost made two factors—raw materials and conversion costs. What wanted the lowest total cost. With prices raw materials fluctuating they do, is, advisable have tech- niques hand suited different types raw materials, that shift may made short notice the com- bination material and technique that most economical. However, one the items con- version costs interest and amortiza- tion equipment installed give this flexibility but held idle periods when its use not economical. The foundry desiring make high- strength gray iron has several recog- nized choices doing it, g., (1) the cupola holding carbon and sili- con the necessary low levels, (2) alloying additions weak iron, (3) cold melting (4) duplexing electric, air furnace, some equivalent. Each these commer- cially used. Technically, the electric melting methods are the most easily controlled and, since they allow use large pro- portions cheap borings and turnings, the economics are whenever reasonable power rates can THE IRON AGE, December 28, b > jae = 3 4 wilt o S a | had, and the turnace can kept busy. However, the first cost electric equipment rather high that interest charges pile idle periods, and this aggravated the demand charge for power which makes the conversion cost rise steeply when the electric unit intermittently oper- ated. Many foundrymen have there- fore had forego the convenience electric unit because there in- sufficient assurance that can kept busy. the other hand, captive foundries large production with assured output have shown great ingenuity developing some the more difficult techniques that can, with enough super- vision, made give very low con- version cost. The jobbing foundryman just breaking into the high-strength cast iron field betwixt and between. not assured steady enough market justify either buying electric unit, developing the tech- nique and control characteristic the large captive foundries making high-strength irons. His usual way out the dilemma use his regular soft iron and load with alloys till meets the high- strength specifications. This un- economical use alloys. has been stated the A.F.A.-A.S.T.M. Sym- good base iron and not used at- tempt make poor iron into fair ” one. theory, least, the duplexing principle should the making high-strength iron, either for use is, for economical alloy- ing make still better irons, and with- out the necessity expensive equip- ment. this possibility that will explored some extent the fol- lowing paragraphs. High-strength iron has already been defined that A.S.T.M. Class 40, e., that which gives 40,000 tensile 1.2-in. bar. Chemically, unalloyed iron, this means metal about 3.00 per cent total carbon, 1.75 per cent sili- con, with the silicon course varied according section, and with some the silicon used inoculating ladle Cast Iron, American Society for Testing Materials, 1933. *C. Morken, “Some Engineering As- pects Cast Mechanical Engi- neering, Vol. 61, June, 1939, p.. 455-459. Judson, “High-Test Iron for Pressure American Association, Vol. 40, 1932, pp. 153-163. MacPherran, “High-Test Cast Iron,” Transactions American Foun- drymen’s Association, Vol. 37, 1929, pp. 495-500. 70. Smalley, “High-Test Cast Iron,” Transactions American Association, Vol. 37, 1929, pp. 485-494. IRON AGE, December 28, addition order produce iron, with the proper structure. possible make stronger un- alloyed iron cutting the carbon still more, and further reduction car- bon and different adjustment sili- con are made for pearlitic malleable, say 2.75 per cent carbon; regular mal- leable, say 2.50 per cent carbon; and super-strength malleable, say per cent carbon; and together with suitable alloy additions for the Ford family alloys say 1.50 per cent carbon. Unless some sort probably not wise overstep the sen- sible mean and try force the base iron too high strength. The super-strength irons have greater shrinkage, higher melting points, and poorer castability. They offer more difficulty getting sound castings. Since the real problem production castings, not test bars. taking the carbon and silicon down the lowest possible level that will give gray castings not necessarily the best answer. calls such iron “tricky.” possible play the upper part the carbon scale the cupola, but the further down the scale the sourer the notes are likely be. Never- theless, Judson’ regularly makes hard iron 2.40 per cent carbon, 1.35 per cent silicon one cupola for mixing with soft iron from another cupola produce final mix about 2.75 per cent carbon, 1.60 per cent silicon for heavy castings. regularly produced metal under 3.00 per cent car- bon from the cupola. Smalley’ also re- ports such cupola iron. all cases, the cupola charge very high steel scrap. There doubt all metal the 2.80-3.10 per cent carbon range desired for high-strength iron cast gray can obtained from the cupola, and cupola malleable regularly made this carbon level. Neither there any doubt that tough job make the cupola con- sistently produce these low carbons and the same time produce sufficiently hot metal. Since the cupola melts the metal contact with the coke, carbon inevitably picked some level governed the metal charge, the coke, and the mode operation the cupola. These factors can more readily controlled give the combi- nation hot metal and small fluctu- ation from the carbon level aimed at, this level set at, say, 3.30 per cent carbon rather than per cent. might said that the average cupola under average operation more “contented” when carbon. Cupola Cheapest Method The silicon level must held low enough that the final addition can made. The minimum addition generally around 0.25 per cent. Hence, the problem phrased the production molten iron 3.00 per cent carbon and per cent less silicon, enough temperature level take the addition and allow plenty time for pouring. The desire much possible the cupola because that the cheapest melting method both first cost equip- ment and fuel consumption. Hence, still more precise phrasing the prob- lem is, the adjustment cupola metal the desired carbon and silicon level. using charge high steel, the silicon can kept low and the desired silicon added later stage, which case the problem merely one low- ering carbon from 3.30 per cent. This can done either oxidation one-tenth the carbon, about per cent dilution with molten low carbon steel. the regular soft iron say 3.40 per cent carbon, 2.20 per cent silicon for use base for alteration the high-strength composition, large di- lution would required bring the silicon where wanted, will sensible oxidize part the sili- con before dilution. “gives down” 3.30 per cent These paragraphs some glib talk about oxidizing carbon silicon these two cases, such oxidation would not adversely affect quality, matter that requires proof. Yet the mere fact that the raw mate- rial has some time been subjected strongly oxidizing conditions need not mean that the final product any the worse. Actually, all out iron oxide ore, and all steel made with blast furnace metal the charge must severely oxidized burn out the carbon the pig iron. Foundrymen know that converter steel cupola metal oxidized most dras- tic fashion before final deoxidation, yet well made converter cast steel very good stuff. Indeed, vigorous boil good medicine for most cast ferrous products. There much reason expect benefit harm from oxidizing step production. any rate, when the melt gotten the chemical composition desired, the first step has been taken toward putting proper shape for casting. Given the desired chemistry, the metal- | | | | | lurgist can usually find out how put the finishing touches. large scale operation, the compo- sition cupola metal satisfactorily has been made blowing part cupola charge and mixing the blown metal with unblown metal and slightly superheating elec- tric. The Ford 1.50 per cent carbon metal for brake drums made Campbell, Wyant Cannon. not verter, as necessary con- the same reaction brought about with solid iron oxide. Kinnear’, following earlier published suggestions Hall”, and unpublished suggestions Melmoth and Batty, duplexed cupola melts charge down cast steel composition oreing down the basic electric. saved half the electric energy re- quired for cold melt, doubled the furnace output and made good grade steel. Such steel practice calls for desulphurizing the cupola metal, but that trick nowadays. use a check the feasibility dropping carbon from the composition which cupola will readily “give down” from all-steel charge, 300 melt 3.34 carbon, 0.21 silicon, 0.22 manga- nese, 0.05 phosphorus, 0.10 per cent sulphur was made basic lined in- duction furnace. With the metal 2800 deg., 6.85 Ib. mill scale was added over period min. When the boiling stopped, sample analyzed 3.04 carbon, 0.04 silicon, 0.07 per cent manganese. Additions ferrosilicon, calculated for 1.75 per cent silicon, and ferromanganese, calculated for 0.50 per cent manganese, were made. sample taken after the additions had become diffused showed 2.98 carbon, 179 silicon, 0.63 manganese, 0.042 phosphorus, 0.084 per cent sulphur. One ladle was poured from the fur- nace once, another after holding min. and third after min., because, from the work Crosby and Herzig™ and other similar data, there was fear that the addition all the silicon SH. Schwartz, “Malleable Made Triplex Process,” Foundry, Vol. 48, 1920, Pp. 815-817, 1925. “Cupola Duplexing for the Electric Steel Foundry,” Metals and loys, Vol. December, 1936, pp. 301-308. Hall, “The Steel Foundry,” 1914, 188. “Late Silicon Additions Vol. 66, January, 1938, pp. 28- ov, fo. Morrison, “Duplexing Malleable Cast Iron,” THE IRON AGE, Vol. 133, June 1934, pp. 19, 76, 80. Bremer, “Superheats and Refines Gray Cast Iron,” Foundry, Vol. 64, 1936, Pp. 26-27, 67. Moore, “The Electric Furnace the Cast Iron Industry,” Transactions Electrochemical Society, Vol. 61, 1932, Pp. 193-201. the ladle would not effective. all cases, the metal was poured 2600 deg. into %-in., 1.2 and test bars. The mechanical properties are shown Table and Fig. All bars were sound. Fig. shows the struc- ture. The only difference from other iroas similar structure and compo- 215 verse strength, lb. c Tran Poured once sition was that the fracture was bit more shiny and more nearly black in- stead the usual gray, which probably ascribable the nice ar- rangement the graphite flakes. With all bars running between 43,500 and 46,800 Ib. per sq. in. tensile and the 2-in. bars between 36,200 and 41,- 900, shown Fig. and Table and with the structure shown Fig. clear that this heat the desired Class high-strength iron and that the silicon addition behaved all right, with ample time for pouring. Thus, reduction carbon solid iron oxide has possibilities. fundamental the oxidation diameter minutes after pig iron steel some inter- mediate carbon content, that the temperature cupola metal, the sili- con and manganese have re- moved quite completely before the carbon attacked. That is, the more readily oxidizable silicon and manga- nese protect the carbon. 1.2 minutes after |—Physical properties iron after reduction carbon solid iron oxide. Chemical analysis: 2.98 Si, 0.63 Mn, 0.042 and 0.084 soft iron, higher both carbon and silicon than desired, first re- move most the silicon, and then the desired amount carbon, therefore not feasible. Oxidation silicon only, followed dilution the melt with molten steel may, however, resorted to. adjustment the charge give the desired silicon, followed duplexing the electric where per cent steel addition made for dilution, has been described for malle- able and high-strength iron Mor- Their requirements for over that the incoming cupola THE IRON AGE, December 28, 9000 Bar TABLE Mechanical Properties Containing T.C. 2.98, 1.79 Si, 0.63 Mn, 0.042 0.084 Obtained Mill Scale Oxidation 0.21 Si, 0.22 Iron. Final Additions 1.75 Si, 0.50 Mn. Size Transverse Poured Test, Cor- Corrected from Bar, rected Break- Deflection, Ladle In. ing Load, Lb. In. 1765 0.194 1 us 1820 0.200 3300 0.376 1.2 3020 0.362 10,920 0.397 1760 0.183 1690 0.174 2890 0.325 2 1.2 2980 0.356 9750 0.413 9800 0.422 1630 0.164 1650 0.163 2770 0.298 1.2 2755 0.301 9900 0.424 10,320 0.410 Brinell, Midway Tensile Brinell Between Impact, Strength, Hardness, Span, Lb. Per Sq. In. Center 50,200 418,000 217 46,800 49.5 44,600 217 214 53.0 40,600 36,200 204 207 50,000 46,750 214 44,800 48.0 43,500 207 207 54.0 41,900 39,600 207 207 46,500 47,000 220 44,000 46.0 44,250 201 204 48.0 40,300 39,400 199 197 NOTE: Ladle was poured just after the silicon addition; ladle min. after silicon addi- tion; and min. after the silicon addition. charge range from 110 kwhr. per ton, something this order must added non-electric practice. first sight this seems tough nut crack. However, there way crack it. The reader probably fa- miliar with thermit welding, and ther- mit steel could conceivably used. Actually, aluminum rather expen- sive fuel, and excess aluminum carried into the iren might not healthy for it. Udy, the Chromium Mining Smelting Corp., posed the use silicon thermit, since excess silicon left over from the reaction compatible with cast iron, and such addition can allowed for. This material being studied Battelle. Instead using iron oxide and aluminum the heat-generating agents, done alumino-thermics, sodium nitrate and ferrosilicon are used. Just the converter, silicon oxidized before the iron, forming silica which fluxed the sodium oxide from the nitrate. desired some lime may added further flux. The reaction generates enough heat melt cast iron chips steel clippings almost instantaneously. The iron the ferrosilicon plus that the chips clippings thus supplied TABLE Mechanical Properties Containing T.C. 2.96, 1.73 Si, 0.55 Mn, 0.18 0.03 Obtained Soda Ash, Mill Scale and Fer-X Treatment Initial 3.35 2.30 Si, 0.70 Mn, 0.18 0.10 Iron, with Final Addition 0.25 Per Cent Si. Transverse Hardness——, Test, Midway Poured Corrected Corrected Tensile Between from Size Breaking Strength, Center and Ladle Bar, In. Load, Lb. tion In. Lb. Per In. Center Outside 1 % 1600 0.160 51,150 241 51,200 1.2 2880 0.228 47,100 223 2970 0.260 47,200 223 10,550 0.301 39,800 207 217 43,100 2620 0.193 45,500 232 2660 0.210 46,000 232 NOTE: Ladle was poured min. after the silicon addition; ladle after further min. 20—THE IRON AGE, December 28, 1939 molten and high temperature. The mixture nitrate, ferrosilicon and metal melted termed “Fer Fer Temperature Addition This method can seen sen- sible one the heat oxidation silicon recalled. About 0.08 silicon required produce Ib. hot molten steel. The heat combustion that amount silicon equivalent about 0.215 kwhr. Therefore, 200 lb. iron added from Fer 1800 Ib. molten cast iron, the proc- ess heat generated equivalent kwhr., but since the heat generated place and almost instantaneously, the efficiency will higher than that the utilization equal number kwhr. the electric furnace, and the Fer addition should ef- electric furnace. the Fer added heated forehearth, its ac- tion should approximately equiva- lent that the usual electric du- plexing method dilution with cold steel. Until the chemists solved the prob- lem nitrogen fixation that the price sodium nitrate came down, would have been uneconomic at- tempt exploit this reaction. Under present conditions affords means making what might termed ladle addition temperature,” the melt produces calculated for the same composition the melt which perature and low carbon melt for di- lution. The silicon the dilution ad- dition can kept low, the desired final addition silicon can made simultaneously the molten state adjusting the Fer composition have excess silicon. trial this method gave the following heat consisting three- fourths briquetted borings, one-fourth heavy scrap was melted down the basic induction furnace calcu- lated composition 3.35 per cent carbon, 2.30 silicon, 0.70 manganese, 0.10 sulphur and 0.18 phosphorus. was treated with soda ash and the slag removed. Mill scale was then added, calculated reduce silicon 1.65 per cent slag removed. Fer was then added for dilution carbon and silicon per cent carbon, 1.50 silicon, and final inoculating addi- tion 0.25 per cent silicon ferro was made. After holding min., set 1.2 and 2-in. test bars was poured, and after min. more, an- other set 1.2-in. bars was poured. The metal was kept 2850 deg. 2650 deg. during the half hour used | J J p Ww applying the various treatments the application power needed. Both ladies were poured 2550 deg. The finished iron analyzed 2.96 per cent carbon, 1.73 silicon, 0.55 manga- nese, sulphur and phos- phorus. The properties are shown Table The structure the metal from the first ladle shown Fig. The fracture this metal was normal. That from the second showed trace tendency toward modification, but IG. 2—Structure high-strength iron after reduc- tion carbon solid iron oxide. the mechanical properties show the second ladle still high-strength iron, that pouring time should ample. The four 1.2-in. bars from this heat ran between the close limits 45,500 and 47,200 Ib. per sq. in. tensile, aver- aging about 46,500. The requirement 40,000 Ib. per sq. in. iron has been exceeded, starting with soft iron melt that was three-fourths briquetted borings. The test does not prove that cupola metal and heated forehearth would easy handle, but does indicate that the chemistry the process does work. suitable heated forehearth would have designed. will also necessary work out chill tests other rapid tests which the composition can checked various stages the process, until the procedure has become routine. first attempt the oreing down and di- lution were overdone, and the result metal 2.44 carbon, 1.56 sili- con, which was white the second ladle poured. Correcting the aim the experience the first shot, the bird was hit with the second barrel. There seems reason why pearlitic malleable cannot made and even regular malleable from soft iron these reactions. The next question whether worth while make high strength special irons either the two ways outlined. Since the tests indicate that the methods suggested are not entirely im- practical, consideration may given how much would cost make high-strength iron such ways. would nice definite figure could set for the cost ordinary soft cupola iron the ladle basis comparison. Actually, this varies greatly with the charge and the cost the charge varies greatly with the location and the date. this connec- tion, would interest digress savings selection the cupola charge. Most the readers know old timers who made money brass and alumi- num castings, not because they were outstanding their molding practice nor because they were better salesmen than their fellows, but primarily be- cause they were skilled scrap and handling their melting practice. The one point which their cost ran under the other fellow’s was the cost molten metal before went into the molds. purchase scrap, taking back from their own customers bor- ings whose composition known, in- telligent mixing the metals with adequate chemical control, use secondary ingot into whose prepara- tion these factors have entered, cut big slice off the cost the charge. When aluminum borings down into ingot and the aluminum content goes down and the alloy con- 3—Structure high-strength iron obtained soda ash, mill scale and Fer treatment, with final addition 0.25 Si. tent up, the foundryman “sweetens” the ingot with sheet clippings. Use electric furnaces where avoidance oxidation losses made thoroughly economical so, the case some bearing met- als, cupola melting when volatiliza- tion was problem, where even allowed the use zinc-containing scrap that could bought cheaper than scrap, made another saving. When materials expensive copper-base and aluminum-base al- loys are being dealt with, these sav- ings are not neglected, and any neg- lect sticks out like sore thumb and intendents. The refiner secondary metals has taken good deal the burden off the shoulders the non-ferrous su- perintendent, but rare indeed that analogous service rendered supplying pedigreed scrap for cupola THE IRON AGE, December 28, t charges. Yet possibilities exist for analogous savings far realized electric melting but not widely real- ized for other melting media. Since the electric furnace operates under non-oxidizing conditions, iron chips steel turnings sheet clip- pings can employed, either part addition duplexing hot metal the electric furnace. Loose borings are not good charge material for any fuel- fired furnace, and the ability use cheaper raw materials than other furnaces that gives the electric unit economic advantage offset the higher cost electric heat. Loose borings are even less usable the cu- pola than other fuel-fired they not only oxidize but they clog the draft. Nevertheless, clean, ings, solidly briquetted under heavy enough pressure, stay together the cupola and melt down like pieces solid scrap. they are only loosely pressed, briquettes disintegrate the cupola and are troublesome loose chips are. This new doctrine. Rayner discussed the advantages high-pressure briquetting before the A.F.A. 1930, stating that, including overhead and amortization, briquet- ted borings for $3.25 per ton, using $60,000 press. discussion, Walls said had done for $1.91 ton. Producers briquetting presses claim can done with steady operation for $1.50 cast iron borings and un- der steel turnings. One user said have made savings equal the cost the press eight months. From user experience, appears that The first cost the press, some $40,000, requires that the kept busy order amortize that cost, and the small jobbing shop obvi- ously can’t put the money for such expenditure. But why doesn’t some enterprising scrap dealer put press, collect borings turnings right the machines the machine shop where they are produced, apply suit- able precautions against rusting that the composition given lot known, and the borings are kept un- rusted, take them the press, briquet them, and then sell these pedigreed briquettes cast iron steel price that will give him profit and make real saving over heavy scrap steel rails? Or, why don’t few foundries get together and operate press serve the whole group? — Rayner, “Briquetting Cast Iron Borings for Use the Cupola,” Transac- tions American Foundrymen’s Associa- tion, Vol. 38, 1930, pp. 460-466. 22—THE IRON AGE, December 28, 1939 TABLE Scrap Prices Per Gross Ton Delivered Consumers, Chicago District No. Cast Spread Turnings No. Steel Spread Average 1939 $8.95 $14.71 $5.76 $8.95 $16.07 $7.12 Average 1988 5.78 12.02 6.24 6.27 6.26 Average 1937 10.49 15.29 4.80 9.81 17.21 7.40 Average 1936 13.26 5.51 7.50 14.72 7.22 Average 1935 6.04 10.74 4.70 6.22 11.53 5.31 Average 1934 6.18 9.07 2.89 5.93 10.18 4.25 ‘Average 4.92 8.21 3.29 4.78 8.02 3.29 Average 1932 3.75 6.82 3.00 will noted that even the calculate the cost high-strength deepest depression when heavy scrap almost given away, borings and turnings are also very low level, but the spread even then the same order the briquetting cost, which may taken per gross ton borings and $2.25 per gross ton turnings. times get better, the lev- els rise and the spread increases two three times the briquetting cost. could considered that the Chi- cago 1937 and 1938 averages are more less representative, 1937 rel- atively good, active year, and 1938 pretty bad one. When preliminary draft this paper was made early June, pig iron, short rails, cast iron scrap, cast iron borings and steel turnings had all had nine months almost complete price stability. Costs could apparently figured with some assurance that they meant something. The events the fall turned this all topsy-turvy, that any one production center the cost ratios the various raw materi- als fluctuated wildly. different calities, the spread and turnings and heavy scrap was va- riously affected. For example, con- sider Nov. quotations Tables III and IV. Such figures naturally create the in- quiry why everyone not doing what few are doing successfully the use briquetted borings for soft iron. Briquetted steel turnings instead short rails for high steel cupola charge offer equal greater oppor- tunity for savings. would appear that with the use briquetted chips turnings, the av- erage cost cupola-melted molten soft iron high steel charge the ladle the Chicago district might have been under $13 per ton 1938 and around $15 $16 1937, includ- ing raw materials and cupola conver- sion costs. Such figures might used more less representative, at- tainable base line costs from which iron. But, instead calculating the basis fluctuating base line, the figuring could confined how much should cost convert cupola into high-strength composition. other words, whatever the cost soft iron the ladle is, try approximate how many dollars per ton must added that cost when making 40,- 000 Ib. per sq. in. tensile iron. Case Soft iron, alloyed from normal charge, with per cent steel addi- tion cut the silicon the desired point, would come out about 3.35 per cent carbon, 1.65 per cent silicon. This could made into high-strength iron final ladle inoculation with 0.25 per cent silicon and the addition suit- able alloys. The carbon too high, and alloy salesmen prefer knock down near per cent possible make their al- loy show best results. But, essary shift this iron into high- strength iron, should the trick add 1919 Ib. it: per cent ferrosilicon, for $0.60 nickel silicon shot ............ give iron 3.3 per cent carbon, 1.9 silicon, 0.6 chromium, 1.5 copper and 0.5 per cent nickel. Or, 1967 Ib. add, per cent ferrosilicon....... $0.60 Ib. per cent ferromolybdenum.. give 3.3 per cent carbon, 1.9 silicon and 0.5 molybdenum, either which should give 40,000 Ib. per sq. in. tensile Case Cold Electric Making per cent carbon, 1.50 0.25 inoculating silicon high- | i — i i - | | | TABLE Scrap Prices Per Gross Ton Delivered Consumers Borings Cast Spread per Machine Scrap Gross Ton $9.50 $18.00" $8.50 .00 19.00 12.00 8.00 16.50 6.50 10.50 17.008 6.50 11.50 20.00 8.50 1 Brokers’ buying prices—Others, prices to consumers. Quoted $16.50 net ton. Quoted $15.50 net ton. strength iron cold electric melting without alloying allows the use large proportions chips ings. But, since these can briquet- ted for cupola use, all that the electric can credited with raw materials Credits Avoidance briquetting about per cent the charge .............. $1.50 Avoidance of cupola melting .......... 2.65 Equal charge for labor, fractories, amortization, etc. ......... 6.05 Iron-silicon for inoculation ............ 0.35 $12.45 Case Electric Duplexing With electric furnace, cupola melt nearly all steel (preferably briquetted turnings) could du- plexed, plus silvery pig for silicon, coming out 3.30 per cent carbon, 1.50 silicon, dilution 1800 Ib. with 200 Ib. loose steel turnings, with the use about kwhr. and in- oculating addition 0.25 per cent sili- con plus little manganese correct for low manganese the steel. And, Case Fer Dilution electric furnace available, this dilution can made 200 iron from Fer which will as- sumed cost per Ib. molten iron produced over the value steel turnings, $3. Excess over value iron, 200 Ib. Fer 3.00 $5.60 Less credits for avoidance cupola melting and briquetting 200 Ib. ...... Turn now the cases adjust- ment carbon and silicon. Case 3.30 per cent carbon, 0.20 sili- con melt made from charge the cupola, and about 1900 Ib. this adjusted per cent carbon, silicon, oxidation, and the 1.75 per cent silicon added the end, the costs the transformatioa high-strength iron figure: Ib. preheated ore mill scale ...... $0.15 Use heated basic forehearth, labor, $4.00 250 silvery pig the cupola charge assumed per lb. over $3.90 cost regular iron. kwhr. (relatively intermittent operation) 1.00 Plus equal amount for labor electric stage, electrodes, refractories, amortization, etc... Less credit for avoidance cupola melting 200 Ib. Less credit for avoidance briquetting 200 Ib. (20c.) Case If, instead producing special cupola melt adjust silicon (as cases and use made every day soft iron 3.40 carbon, 2.20 silicon, and adjustment composition accomplished wholly outside the cupola, 1750 lb. this melt, may added, heated basic forehearth, Ib. preheated ore, making the composition 3.40 carbon, 1.70 silicon. this added 230 iron from Fer and silicon. The costs figure out: Use heated forehearth ........ 1.00 230 Ib. iron from Fer over Less credit avoidance cupola melt .30 Summarizing, the estimated cost 40,000 Ib. per sq. in. iron over that ordinary every day cupola melt has figured out follows: Case A—Alloying soft iron ....$8.75 $9.25 Case B—Cold electric 8.3 Case dilution high steel Case D—Fer dilution, high Case E—Removal carbon from high 4.60 The high steel charge the cupola, whether steel scrap briquetted turn- ings, will ordinarily cost bit more than cast scrap briquetted borings, and little more coke will required, which factors have not been consid- ered the above comparison. The cost Fer may have been taken little high. The estimate per ton for the heated forehearth probably generous too. Thus, the last four methods are likely even cost that would hard distinguish among them the economic basis. The last three methods indicate that the production 40,000 Ib. per sq. in. tensile iron should capable ac- without requiring very expensive equipment and without materially al- tering ordinary cupola practice, for per lb. metal the ladle over the cost soft iron. The 40,000 Ib. iron will proper base for efficient alloying still higher strength irons. The last three methods look interest- ing for foundries the transition pe- riod while the demand for 40,000 Ib. iron yet not sufficient allow its (CONTINUED PAGE 46) THE IRON AGE, December 28, > | Less for avoidance cupola melting SNOW HEN the 37-ton Byrd snow cruiser plunged into near Lima, Ohio, its recent trip Chicago Boston, the strength its welded steel construc- tion was given severe test. Damage was slight, however, and the huge machine proceeded its own power after being extricated. Weight saving enabled welding and the use high gives the machine cruising range around 5000 miles, while some its principles construction suggest pos- sibilities for designers buses and kindred equipment. deg. below zero the high tensile low alloy steel used will withstand impact stresses 24—THE IRON AGE, December 28, 1939 times greater than ordinary steel. has about per cent more fatigue strength, its tensile strength per cent higher, strength about double and resistance corrosion stated being times that ordinary steel. Furthermore, easily fabricated and welded, and normalizing relieve welding stresses does not alter properties. Throughout all the framing there was other means fastening used than ing. Lincoln Electric Co. equipment was employed the company doing the fabricating. Tacking the beams the bending stage was facilitated are welder, and the beams were welded onto steel horses until the cruiser was com- pleted. This construction shown the accompanying photo. Such parts pressure blocks, steer- ing post, brackets, angle blocks, steer- ing post bottom plates, tail gate, doors, steering pistons, motor generator bases and steering cylinders were fabricated units. general jigs were not economical use, there were too few assemblies warrant them. After the tack welded the vertical members weld points were located and sure block posts were the first j up. The cross headers over these were located and tacked place, diagonal beams followed; then the beams between the wheel headers. Bottom side ribs came next with hori- zontal members. All these were located and tack welded. Wheels Arc Welded this point other minor members were located and tack welded. When any portion the was possible check unit, the are welding was started. While the framing went forward arched sheets were being fitted and tack welded between the beams the underframe. About one-third the total welding footage the cruiser the underframe and the arched sheets. All heavy sections were out for are welding and welds were continuous around all members. The wheels the cruiser, each weighing 810 Ib. complete, diameter with tire installed, are are welded construction also. Weight the live load, yet strength and rigidity Were retained. Disks were formed outwardly the outside diameter make the tire re- tainer and skeleton the wheel. Two ameter were formed and welded the skeleton disk make the bead casing support for the tire. connect the two disks together and complete the felloe band, flat steel plate ft. in. long, in. wide, 12-gage Inland steel was used. This was rough hot formed sections, using male and female die. Assembled, the band had inner diameter 5734 was formed sections, assembled and trued up. The workability the high tensile steel was demonstrated the working operation the felloe order test the dies, strips com- mon grade steel were first formed. steel failed. Every piece high- tensile steel passed through these dies was perfect with 20%-in. lateral sweep and rim radius in. Be- fore being formed each piece was ap- proximately 7034 in. shaping, take-up was found about in. measured along the inside arc, and stretch the outside are was in. Welding Stresses Relieved The various parts each wheel were ground preparatory assembly. bead casing support was then weld- to, the inside each disk. The placing one disk stools mounted heavy face plate, the disk being leveled means shims. The 12- gage felloe band was then placed position and the other disk was low- ered top. Spacer blocks were used between the two disks assure paral- lelism and correct spread. This as- sembly was tack welded chuck blocks fitted with adjusting set screws were used assure accurate diameter. The wheel was then firmly ~ secured the face plate four heavy clamps. All welding possible was com- pleted with the assembly held After removal from the jig, eighteen 12-gage cross ribs were welded the disks and the felloe band. Dimensions were the same after this operation except for uniform shrinkage the tread the wheel. All form- ing and welding stresses were relieved normalizing. Machine Ft. Long The body assembly was tacked to- gether and chuck blocks with adjusting set screws were used bring accurate diameter, after which the complete assembly was clamped the face plate and welding the unit proceeded. removal from the jig, cross mem- bers were fitted between the disks and the felloe band. These were welded completely with the wheel normal position. The snow cruiser, illustrated herein, was designed and constructed and for the Research Foundation Ar- mour Institute Technology under the supervision Dr. Thomas Poulter. The machine ft. long and resembles transcontinental bus. Its speed range between miles per hr. addition scientists and much equipment, the cruiser designed carry airplane its back. Some ft. the tail the ma- chine will cut off order facili- tate loading vessel Boston. Reassembly welding will carried out Little America. THE IRON AGE, December 28, j ‘ sit | 2 a tk > INDUCTION HARDENING DRILL HUCK BODIES NDUCTION applied drill chuck bodies has highly satisfactory results recent months for the Jacobs Mfg. Co., Hartford, Conn., which employ- ing Tocco Junior unit, compact machine especially designed for small parts the Ohio Crankshaft Co., Cleveland. The chuck manufacturer has found necessary harden only the area subjected wear. This the nose the chuck, including the key wrench pilot holes. Previously the whole front end body the chuck was heated throughout harden the area subjected wear, but because the irregular cross section the body, distortion the was likely occur, making difficult secure the accuracy required the finished chuck. Under the new method the jaw sockets are not heated, there dis- tortion and the wearing surfaces are more uniformly heat treated hard- er, longer-lasting surface. Substantial savings have been through elimination rejections due distortion insufficient hard- while actual production costs for the hardening operation lowered. The heat treated area produced the Tocco electrical hardening process tests Rockwell the scale, with metallurgical structure highly resistant wear and abrasion. The Tocco Junior unit little larger than shop bench, though com- pletely self contained. equipped with specially designed built-in high 26—THE IRON AGE, December 28, 1939 frequency current second accuracy insured, the same the larger hardening machines. Time cycles and power input are pre-set and the hardening cycle au- — tomatically controlled. The placing bodies within the inductor coil the only manual operation. The Tocco process used harden- ing Jacobs drill chucks was developed Junior induction hardening machine, which little larger than shop bench, though completely self contained. (Ohio Crankshaft Co.— Jacobs Mfg. | } | | | | — 4 ey we x #3 originally for the reduction wear journals and crankshafts. has been adapted many other fields, including cam shafts, drive shafts, axle shafts, valve tappets, rocker arm shafts and track pins. The localized heating for harden- ing accomplished subjecting the area hardened the high fre- quency magnetic field produced the passage high frequency current through coil which sur- rounds but does not touch the area hardened. The high frequency magnetic field causes heating the desired area the combined heating effects hysteresis and eddy currents. accompanying the use high frequency current “skin effect” which confines heating the skin surface the piece being heated. The source the high fre- quency current the process spe- cially designed high frequency con- verter built into the machine and op- erated from the ordinary available shop power supply. This inductive heating, named because the heating result in- duced current the piece, extremely fast, rarely requiring more than few hardened has reached the desired tem- perature, the power automatically shut off and the heated area quenched pressure spraying through orifices quenching jacket, which in- tegral with the inductor coil, without moving the piece hardened. production, the operator places chuck body the inductor coil shown the accompanying photo and pushes button which starts the Tocco hard- ening cycle. the completion the the hardened drill chuck and inserts another for heat treatment. The heat- ing and quenching cycles are auto- seconds. Fastening Device Nails Metal Parts Together NEW fastening device, called Speed Clip, has recently been developed the Tinnerman Speed Nut Co., Cleveland, fasten metal parts together without the need gain- ing access the opposite side the assembly. The device itself tubu- lar-like formation spring steel. The end the Speed Clip that enters the hole curled-in, while the other end seats with its flange. this enter- ing position, tongues either side are compressed into the body the clip, but with clip fully inserted, the two cam-like tongues spring out and lock the clip firmly the hole. When the view showing chuck body position for hardening. Only the area subjected wear must treated, contrary previous practice. (Ohio Crankshaft Co.—Jacobs Mfg. matically controlled with accuracy plus minus 0.05 second. The power input, length heating cycle, quenching pressure and time quench- ing are pre-set for the part locally surface hardened and automatically controlled that the only function place the part the inductor coil and push button. This insures absolute accuracy heat treat- ment and duplication results. When required change the stud pushed completely “home,” the clip fully expanded and the curled- end the clip bites into the stud lock securely. This assembly method adaptable most any part such name plates, trim strips, me- dallions and the like. With slight variations design, this Speed Clip may used perma- nent lock, removable lock slideable grip tvpe. the second type. predetermining the amount pull desired for removal, the curled-in end the Speed Clip formed with the correct degree bite. The slideable grip type recommended where studs are made relatively soft plastic materials such cellulose acetates. set-up from hardening the No. the No. chuck body, for example, the operator replaces the No. induc- tor coil with the No. inductor coil. Only two hose connections for the quench supply and two electrical leads the coil need adjusted for this replacement. The predetermined hard- ening factors are then set the con- trol dials and the machine ready for operation the new change made min. TINNERMAN SPEED CLIP INTEGRALLY FORMED STUD RIVET WHEN STUD PUSHED COMPLETELY “HOME” THE CURLED-IN END THE SPEED CLIP BITES INTO STUD LOCK SECURELY PERMANENT LOCKING TYPE LOCKING TYPE TYPE THE IRON AGE, December 28, ~ 1 ; x rs q j q MONG the machine tools introduced re- cent weeks are number grinders improved design, also several unconventional types such the jig grinder, generating style machine for correcting errors hole size and placement re- entirely new universal grinder known the type multi- purpose announced Norton Co. Worcester, Mass. Being universal machine, performs both external and internal grinding opera- tions. number interesting fea- tures have been incorporated the design. The table can hydraulically hand through two-speed arrangement, thus making possible move the table quickly shoulder grinding and similar opera- tions. Two ranges wheel feed are provided, either which selected pushing pulling out single which the handwheel can located either for external grinding internal grinding. electric dwell control for the hydraulic traverse mechanism sup- plied part the machine equip WHA NEW sult heat treatment pre- cision steel parts. com- bination cutter and surface grinder has also been an- nounced. New designs bor- ing, engraving, honing, mill- ing, planing, sawing, turning and threading are similarly highlighted this review. ° ment, enabling the operator easily adjust the amount dwell each table ond. The headstock the universal type and powered either RONT view the new semi-automatic grinder shown with hy- draulically operated for the type grinder, all motor starting equip- ment housed ina cored receptacle the rear, protected from dirt and moisture. Standard electrical equipment used, actuated the push buttons the front. constant through cone type V-pulleys adjustable speed motor. either case work revolution push button Final drive the face plate chain. live spindle and dead center operations can performed. The base graduated and can set any desired angle either side the zero normal position. The wheel slide can swiveled any desired angle and fed this angle, can set any angle and fed perpendicularly the table ways. releasing single binding screw, possible move the wheel unit proper backward for- ward, thus distance LEFT way guards add the neat appearance the Norton type multipurpose grinder, shown the in. length. Base sturdily ribbed single casting with reservoirs for coolant ond hydraulic oil cast in. All push- buttons and starting switches are built flush with the front the machine. ~~ | | i | | | ° | of ° q > ACHINE between wheel and work centers much advantage when per- where the headstock deg. The internal spindle bolted the front the wheel slide and driven flat belt from the same motor that drives the external spindle. Wheel drive motor can reversed, feature which was provided for internal and The machine swings in. and built 24, 36, 48, and in. lengths. j THE New Doall grinder may used universal cutter grinder precision surface grinder, simply interchanging t