The Iron Age 1940-03-21: Vol 45 Iss 12

President and Editor BAUR Vice-President and General Manager Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors Washington Editors Resident District Editors CAMPBELL ROBERT BINGHAM Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR FIDRMUC | Boston Hamburg, Germany MEYER CHARLES POST Milwaukee San Francisco SANDERSON CLYDE ENNIS Toronto, Ontario Birmingham 4 Newark, N. J. St. Louis Jr. Again the Machine—and Jobs! Buffalo Pacific Coast Steel Industry Welding Aluminum Aircraft Alloys DIX, Manager Reader Service What Plastic Use? ADVERTISING STAFF Emerson Findley ? 621 Union Bldg Cleveland Sheets—A Structural Material 39 Robert F. Blair ons B. L. Herman, C on dg., Phila. - 1012 Otis Chicago Interpretation Test Results H. E. Leonard, 239 W. 39th St., New York . Peirce Lewis. 7310 Woodward Ave., Detroit e 239 39th St., New York Speculum Metal Revived W. J. Fitzgerald § 428 Park Bldg., Pitts. Warren, Box 81, Hartford, Conn. Casting Temperatures for Aluminum Don F. Harner. 1595 Pacific Avenue, Long Beach, Cal. D teel Fac Member, Audit Bureau of Circulations e les for Drop Hammer Work ee 46 Member, Associated Business Papers Indexed the Industrial Arts Index. Statistics Metal Working Activity Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- the Assembly Line ada, $8.50; Foreign, $12.00 a year. Single copy, 25 cents. Annual Num- ° ber $1.00. Cable Address, ‘“‘Ironage, Washington News 54 CHILTON COMPANY (Incorporated) Plant Expansion and Equipment Editorial and Publication Office Executive Offices vr vwvreyv Chestnut and 56th Sts., 239 West 39th St., Philadelphia, Pa., U.S.A. New York, N. Y., U.S.A. Free Industrial Literature GEORGE GRIFFITHS, EVERIT TERHUNE, Vice-President Just Between Two 105 VAN DEVENTER, Vice-President Cc. 8S. BAUR, Vice-President Index to Advertisers 134 WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS L. KANE, G. C. BUZBY, P. M. FAHRENDORF HARRY DUFFY Copyright, 1940, Chilton Company (Inc.) 5 3 Fy | x | r | i tng } | ‘ Jat | Any straight carbon tool steel which can made into die and punch like illustrated result careful selection raw materials and melting, refining and pouring practice maintained high them. standard. The tools illustrated have been service for » prac years punching soft steel .125" thick. unusual appli- cation for straight carbon tool but those who know Pompton expect and get the unusual. Pompton its various carbon tempers can used over wide range applications. good straight carbon tool steel carry regularly More details about Pompton will found the folder. Send the coupon for it. Please send me: Certified Blue Sheet Pompton 0 New folder entitled “Straight Carbon Tool Steel in your Production Name.... Company. Tool, Stainless, Carbon and City...... Electrical Steels A | A ... THE IRON AGE ... MARCH 21, 1940 ESTABLISHED 1855 Vol. 145, No. Again the Machine—and Jobs! ARLY next month the TNEC will put machinery the witness stand Washington. Continuous steel mills and forging machines, lathes, planers and automatic production machines all types will asked this question: you cause unemployment?" The answer that the machine gives this question before the Senate Committee which Mr. O'Mahoney chairman may decide the fate his Senate Bill introduced him last week, which seeks establish system discriminatory taxes and tax rebates for the purpose stimulating the employment more people industry, distinguished from the employment more machines. The principle Senator Bill based upon the theories put forward Karl Karsten, who was formerly WPA statistician and before that forecaster specializing economic advice in- vestors. The article which Senator Bill based, reprinted his request the Con- gressional Record, briefed for the benefit our readers elsewhere this issue. should carefully read all those who are interested the subject mechanization, because the prominence given and the ideas its author the Senator from Wyoming, who its sponsor. have quarrel with any sincere and intelligent attempt mitigate the hardships incident the unemployment problem which has confronted this country throughout the whole President Roose- Administration, and would the last charge Senator O'Mahoney with insincerity. Offset- ting this, however, must said that the Senator's background during the past years would presup- pose experience more intimately connected with cows than smokestacks. And this opinion reinforced his advocacy plan which reveals itself upon critical examination likely induce employers forsake machinery for hand work might persuade the moon reverse its course the heavens for the sake one per cent tax rebate. For this proposal not tax the machine, nor incentive employment—it tax efficiency. Our chief criticism, however, this connection must not directed against such well intentioned men the Senator Mr. Karsten, who least are trying something about this problem. Cen- sure must fall upon the employers our American manufacturing plants who have not yet seen the necessity taken the pains acquaint the public with the real facts the matter. have for one thing, demonstrated what really small percentage total unemployment due men being displaced machines. With over per cent those out work the category common labor which has never been associated with mechanization higher than that the pick, shovel, and wheel- barrow, this should not impossible task for fairly intelligent statistician. the machine and jobs. Let's hope that get the bottom this matter now, once and for all. i 4 if F ER 4 3 1 } > j it il | AS 23 ! 50% lighter with equal Extra profit comes from more pay load, and more pay load gained reducing dead weight. Inland Hi-Steel, with twice the yield strength ordinary HI-STEEL carbon steel, makes possible the cutting structural weight 50%. Inland Hi-Steel fabricates easily, This chart shows the comparative weights Hi-Steel part and bon steel part equal strength. welds economically priced. Write today for Inland Hi-Steel Bulletin No. 10. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS — ORDINARY CARBON STEEL Dearborn Street, Chicago Sales Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas City, there was Pacific Coast steel all depends what meant steel industry, and how, when and where developed. First, Washington (D. C.) proclaims the West Coast ripe for the development its own steel industry. And crowding along was kaleidoscope inspired statements and newspaper treacle regarding matters military strat- electric furnace technique fuel—revolutionary charcoal iron—Los Angeles the steel giant the future—dirt-cheap electric power turning con- ventional metallurgical practices topsy-turvy. There’s vista new wood coke metallurgy bursting its bonds and opening new frontiers. The eyes sparkle and the pulse quickens. all quite exciting. Certainly the sapience the political mind demands admiration, least technical-wise. new industry born decree. But still all seems too casual, too simple. brings mind the Indiana legislator about years ago who introduced bill change the value from LIPPERT, Metallurgical Editor, The Iron Age 3.1416 even just make mathematical calcula- tions more simple. Most the published fumbling and confusion regarding the Pacific Coast enterprise reflection the electrical reduction the ore involved. There general awe electrical power, and the reduction practice completely strange this country. Nonetheless, technical and cost data have been pretty well established abroad. There gainsaying the fact that excellent iron can made, even with low-grade ore and fuel. But whether such practice the Pacific Coast competitive today out-points the lowly and much maligned blast furnace are moot questions indeed. number factors are involved, for instance the markets for finished product, existing competitive industry, quality and location ore and fuel, and above all the electric power cost. Each these fac- tors for the first time examined the following pages. And, figure the writer will, the critical power cost seems come out less than one mill means the Government must dump power far less than cost. THE IRON AGE, March 21, 1940—25 a ‘ q STEADY intensification activity characterizes the Far West, and the hum enterprise there has for some time been pitched higher than other sections the country. examination shows that Idaho, Arizona, Utah, Nevada, Washington, Oregon, California—the seven Pacific Coast states roughly west the Rocky Mountains—contribute almost $3,000,- 000,000, about per cent the manufactured wealth the United States. Somewhat over per cent the petroleum refining done that area; per cent the canning and pre- serving fruits and per cent the canning fish, crabs and shrimps; per cent the canning condensed and evaporated milk; per cent the coun- try’s lumber and timber products; over per cent the meat packing; and about per cent all other manufac- turing activities, which includes rapidly plane industry. The population the area over 10,000,000, per cent the country’s total, and growing rapidly, having increased per cent between 1920 and 1930 (which was before the Dust Bowl migration), compared with growth 16.1 per cent for the United States whole. Furthermore, the buying power the population nitely higher than the United States average. How industries and this population shape regards steel consumption? First, will noted that the dominant industries not involve large steel consumption, with the obvious exception the canning and preserving industry which requires large quantities tin plate. There regrettable absence data relative the distribution finished steel products states regional markets either the American Iron and Steel Institute the United States Bureau the Census. However, some time ago the writer various means collected infor- mation steel consumption number different states, which data are believed relatively accurate. Total steel consumption the block states made Idaho, Arizona, Utah, Nevada, Washington, Oregon and California for 1940 judged being somewhat more than 2,000,000 gross tons. This volume considered normal market for the year and predicated upon aver- age business conditions obtaining. The possibility un- usual business conditions cyclical trends ignored. This approximate 2,000,000 gross tons finished steel consumption for the seven Pacific Coast states could broken down roughly follows: Product Gross Tons Tubular products 672,840 Tin plate 382,000 Bars and light shapes 240,000 Wire, rods and wire products 191,990 Heavy structural shapes 124,760 Raiis, light and heavy 127,100 Black sheets 110,390 Galvanized sheets 96,400 Angle bars, tie plates, etc. 49,980 Strip, hot and cold 27,200 2,900 Note the wide diversification the line products sold. This, and equally wide diversification custom- 26—THE IRON AGE, March 21, 1940 ers, results complicated sales problem the Coast, which problem would even more complicated were not for the fact that there high concentration sales the Los Angeles and San Francisco districts. The question naturally arises how this demand currently being satisfied. For some time the Coast has had rather neat little steel industry its own although that fact seemingly somewhat obscured the vocalization about new industry. The Columbia Steel Co. (U. Steel Corp.) has three plants—at Pittsburg, Cal.; Cal.; and the Works San Fran- cisco, All three have ingot capacity about 410,000 tons. Bethlehem Steel Co. has plants South San cisco, Los Angeles, and Seattle, with total ingot capa- city 380,000 tons. There are also two independent Northwest Steel Rolling Mills, Ine., Seattle, with about 15,000 tons ingot capacity (electric furnace with scrap charge used); and Corp., Oakland, with about 76,000 tons ingot There are also two re-rolling mills: Simmons Co., San Francisco; and West Coast Pipe Steel Co., Los \ll these producers will this vear contribute probable 670,000 tons finished steel, distributed roughly lows Product Gross Tons Bars and light shapes 312,000 Wire, wire products, and rods 120,000 Black sheets 92,000 Tin plate 40,000 Angle bars, tie plates, etc. Heavy structural shapes 36,000 Plates 12,000 Cotton ties and hoops 2,000 Pipe, tubes and all other 16,000 The ditference between consumption about tons and local production 670,000 tons tons, which undeniably neat wad But, note that the deficiency mostly highly finished products, being conspicuous tubular products (over 672,000 tons), tin plate (342,000 tons), and galvanized sheets (96,400 tons). heavy steels there pronounced deficiency rails (127,100 tons), heavy shapes tons), and plates (191,020 tons). It’s quite obvious from what parts the country goodly part these deficiencies are made and Sparrows Point, Md., the two highly developed and integrated steel making units blessed with water transpor tation that permits shipment into the Pacific states over-all freight rate less than any the other steel plants the United States. the total deficiency 606,000 tons, the writer would guess that perhaps close 400,000 tons originate Birmingham, about 300,000 tons Sparrows Point, and the remaining 906,000 tons come from scattered points throughout other sections the country. view the great deficiency Pacific manufacture and the fact that both Bethlehem and Colum- bia already have steel making facilities there, the query might raised why the steel making capacity not raised. The author would surmise that slow increase contemplated both companies, but quick expansion precluded for several reasons—one that k NW NNW} \\\ | \\ \\) > WA 4 Wi \\\\\\\ } | } 5 A | | \ | | | | lron Ore Manganese Ore Limestone HN \\\\}} | | \ x ) ) Coking Coal ~ ve \\ ‘ 4) ba! F MINARETS q { * PIOCHE a 1BON SPRINGS ORIENT be, CANYON CREEK FIERRO HERCULES iH] DEL MERCADO | Cuyuna TEXAS \\\\\\ \\\ \\\ \ mingham and Sparrows Point are excellent low-cost base- load plants from which supply such deficiencies; and the other being most prosaic thing, the supply scrap the Pacific Coast. The manufacture steel the open hearth the Pacific Coast still pretty much limited the amount scrap available there the open market. general the competition for available scrap not brisk enough drive quotations excessive values, and the price usually averages about under comparative values the However, drastic change the relation between supply and demand could wreak with the scrap situ- ation—steel making costs might well rise decidedly uncomfortable level. Pig iron used with the scrap improve the quality the open hearth ventional practice throughout the country) and augment the raw material supply, but the amount this iron coming from Provo, restricts the use average about per cent the charge (which less than average United States practice). With the market for steel (unsatisfied locally) the Pacific Coast and the reasons for failure expand exist- ing capacity there along conventional lines both set forth far series specious steps, this discussion now comes the projected electric furnace reduction Coast ores basis additional steel industry there. Cer- tainly there would ready market for such steel competitive price-wise, and new plant would likely first into pig iron production for foundry work, broaden out into bars, cotton ties, and rods and wire, all products which not require extremely heavy capital investment rolling and finishing equipment, nor concentrated loads carry the in- vestment charges. The questions now interest are potential ore and fuel supplies, the cost electric current, and the economic and technical features electric furnace reduction ores. Electric Furnace Smelting reduction iron ore the United based pyro-metallurgy, using coke (from coal) reducing agent and fuel. Many years ago char- coal was employed, but the forests fell the costs became States 1Columbia’s furnace Provo has available coal supply (own, and Government lease) for probable 100 years oper- ation. The coal makes weak coke but one which has given excellent results the blast furnace. The ore outcrops the side Iron Mountain southwestern Utah, 244 miles from the blast furnace, and mined from open pits. The ore aver- ages 54.5 per cent Fe, non-Bessemer character, and available quantities sufficient for about 100 stone in ample quantities is nearby. Iron production generally about one-half foundry grade for merchant sale the other half being steel-making grade for own use. Smelting Iron Ore the Norwegian Furnace,” Hole, Jernkontorets 121, pp. 1937. “The Tysland-Hole (Spigerverk) Furnace For Smelting Iron Hole, Teknisk Tidskrift, 69, Bergsvetenskap, No. pp. 9-11, Feb., 1939. “Erzeugung Von Roheisen Mit Helfe Elektrischer Energie,” Durrer, Ztschr. Elektrochem., Vol. 42, No. 1936. “Low Shaft Siemens and Halske Furnace,” Stahl und April 14, 1938. “L’Usine d’Aoste de la Societa Nazionale Cogna,”’ Journal Du Four Electrique Des Industries March 1938. Pig Iron Electric Furnace from Pyrite Sin- Giuseppe Ongaro, Chimica L’Industria, February, “Pig Iron Production Annaler, 1934, Vol. “Aufgaben des Lichtbogen-Reduktionsofens der Eisen, Metallhutten and Chemischen Industrie, Kauchtschisch- wili, Siemens-Zeitschrift, 17, 1937, No. Durrer, with Electric Jernkontorets 28—THE IRON AGE, March 1940 few countries abroad where fuel sup- plies are scanty and electrical power has been readily and cheaply available, the combination has lead electric smelting iron ores whereby portion the fuel cus- tomarily used has been replaced the prohibitive. The principal development this practice has been Sweden and lesser extent Norway, Finland, Italy, Japan and southern France. also been several abortive efforts develop similar prac tice Canada and the United States. years all those countries which electric metallurgy has expanded, the process used almost exclusively for the production pig tron. After the pig iron produced has converted into steel, and the fuel for that purpose usually (as this country) ordinary type such gas oil. And course the production steel from scrap the furnace the are tion type common throughout the world, being used ex- tensively the United States (for instance, Northwest Steel Rolling Mills, Inc., mentioned earlier this article). However, the combination pig tron electric power therefrom electric power rare. the author, there are certain tures which make the conversion pig iron electric furnace uneconomical operation other means are available. All the recent discussion new Pacific Coast steel industry has centered the use electric power for pig tron production, drawing current from Federal projects Washington, Oregon and Arizona, and perhaps also from the Central Valley project California. Not only will the making pig iron that manner dis- cussed, but the making ferroalloys, and the conversion pig iron into steel means electric likewise covered, these latter two sibilities have also several times been suggested. ‘There fair volume foreign literature available regarding the technical features and cost such electric furnace conversion, and information from this will drawn heavily examining the technical factors and costs involved. The production pig iron electric smelting fur- nace simple operation and has been brought maximum state efficiency Sweden where three factors contributed its high-grade ore, cheap power from hydro-electric stations which have been easily devel- oped, and forests from which timber for the production charcoal could obtained cheaply. other countries where these conditions were not favorable the ations have been less Norway has plies good ore, cheap power, but has lacked charcoal. Consequently, there have been attempts use coke but two three outstanding experiments the enterprises failed for reasons which that time were inherent the use coke instead charcoal. Later developments led some success with mixture charcoal and coke with coke alone but with some increase power consumption. The furnaces originally used Sweden somewhat re- sembled the coke blast furnace customary the United States. Later, there was modification the furnace lines and construction developed which sembled electric steel furnace above which was small blast furnace shaft. This has been satisfactory where char- coal the reducing agent. Most the Swedish furnaces now operating are this type. The difficulties with the use coke reducing agent =~ | | | | | | e — have led modifications furnace design and the last years the Swedish so-called furnace has been replaced other countries pit furnace which essen tially shallow brick-lined box into which the materials are charged from above. This type furnace ously been developed for ferroalloys and metallurgical products, and its success led the use for pig iron. The principal development has been in-Norway where Tysland, furnaces this type have been oper ation for vears. this page show the construction the Swedish shaft furnace and the pit furnace and illustrate the construction differences. comparison between the material requirements the conventional blast furnace used the United States and the electric furnace used for pig iron tion follows: Blast Electric Furnace Furnace Ore Same Same Fuel 1800 Ib. 800 Fluxes 800 400 Power kwhr. 2500 kwhr. Electrodes Blast 3.5 tons Surplus top gas avail- per cent per cent 480 able for extraneous heating use value coke, 550 This comparison shows that 1800 fuel and tons air-blast have been replaced 800 Ib. fuel and 2500 kw-hr. plus Ib. electrodes. Without giving consideration the limitations the sizes each type and the effect size labor per ton, comparison operating costs comes down principally the difference between these two combinations fuel, electrodes and power. (After all, the cost blast measured largely the cost the power supply it.) The small difference (Left) Swedish shaft type electric furnace. (Right) Low shaft electric furnace developed Tysland, Norway. the flux requirements will have little effect the iron cost because this customarily cheap raw material. the overhead costs and the cost fluxes are neg- lected, electric pig iron involves net consumption 320 suitable fuel, 2500 kwhr. and Ib. electrodes. The customary coke blast furnace requires for its operation 1250 Ib. (1800 Ib. less surplus gas equivalent) good blast furnace coke and tons air-blast. The surplus blast furnace gas derived deducting all blast furnace re- quirements (blowing, stoves, from the total top gas produced, estimating the surplus available for power which appears the preceding table. The cost blast Greene, well-known and able Seattle electric furnace maker, constructing unit from those used abroad. described tilting type, 3-phase multiple electrode unit, with closed top, through which the electrodes are suspended into the bath. Coal used reducing agent. The furnace equipped with auxiliary rotary drying kiln into which ground ore, coal and flux fed, dried and discharged directly through closed feed-hole into one end the furnace. Tapping the slag and charge the opposite end. Gases, principally CO, pass out the furnace countercurrent the flow ore, preheating and partially pre- the ore drops from the kiln onto the furnace THE IRON AGE, March 21, 1940—29 per ton iron this comparison, therefore, reduces itself the additional items labor, repairs and supplies. For furnace having capacity 1000 tons per day, ing costs will not exceed 30c. per ton. The costs the items for the two types furnaces follow: Blast Electric Furnace Furnace Fuel per ton $4.50 $2.00 Electrodes 5c. 1.25 Fluxes 0.60 0.45 Total $5.40 $3.70 Surplus gas credit 0.93 0.62 Net cost $4.47 $3.08 Power equate costs 1.39 $4.47 $4.47 Power per kwhr. permissible equate costs 0.55 mill. This table shows that coke can had per net ton delivered the furnace site the cost power for electric smelting cannot exceed 0.55 mill per kwhr. coke cost not easily obtained any point the Pacific Coast. more probable figure about $6.50, which would make equivalent cost power 0.84 mill. However, these figures wholly neglect the effect the size the furnace labor, supplies, refractories, repairs and all the other factors which enter into pig iron production, Thus far the electric pig iron furnace has been re- stricted relatively small sizes, and furnace having capacity 12,000 kw. large unit, although bigger furnaces appear possible with the newer developments furnaces the Tysland type. furnace having capacity 16,000 kw. operating with per cent load factor could produce 50,000 tons pig iron yearly. Such furnace would likely cost about $350,000 this coke blast furnace having capacity 1000 tons daily could produce 330,000 tons per year, hence seven electric fur- naces the largest size would required replace one coke furnace modern type. The coke furnace itself, including blowing equipment but exclusive all ore-han- dling and stocking facilities, coke plant, etc., would cost per- haps $3,500,000, $1,000,000 more than electric furnaces the same annual capacity. course, can assumed that the ore-handling system stocking facilities are about the same for equal output. There one very large factor electric smelting installation which greatly increases the investment cost. Seven furnaces, each 16,000 kw. transforming capacity, would represent connected load 112,000 kw. Irregularity operation and diversity factors would re- duce the average load not more than 80,000 kw. provide for peaks and spares plant 100,000 kw. would required. Unless conditions are exceptionally favorable not all the cost charged power alone, such plant would cost not less than $80 per kw. $8,000,000 would need invested furnish the power which such plant would absorb. Both plants would need coke supply. The coke blast furnace would use 300,000 tons coke annually, while electric furnace would require only 135,000 tons. tons coke per oven-day, the coke furnace would require ovens and electric furnace ovens, difference ovens approximately $1,500,000 investment. The costs the two coke plants would $2,700,000 and $1,200,000. The total investments for the two types plant the alone which have been considered the preceding paragraphs follow: 30—THE IRON AGE, March 21, 1940 Blast Electric Furnace Furnace Furnace ... $3,500,000 $2,450,000 Power plant 300,000 8,000,000 Coke plant 2,700,000 Total $6,500,000 $11,650,000 The above comparison shows that investment purely electric smelting installation having the capacity produce about 330,000 tons pig iron yearly would nearly twice great the investment needed for single coke blast furnace rated 1000 tons per day. Some items have been neglected both cases and when these are comparison between the two plants will favorable coke blast furnace, but nevertheless latter much less costly build. The comparison production costs earlier table disclosed that with coke even per ton the power must applied the electric furnace considerably less than one mill per kwhr. investment cost for hydro- electric installation amounting $80 per kw. will repre- sent about $100 per kw. average yearly output plant most favorably situated and having most favorable yearly load factor. With 8700 hr. yearly operation per cent charge this investment represents nearly one mill for capital expense alone. this must added operating expenses, investment transmission lines, line maintenance and conversion and trasmission losses. thus evident that power one mill per kwhr. not obtainable figure with present day construction costs. All the investigation the writer has been able make discloses that the lowest price quoted Federal agencies 1.5 mills for power Bonneville, where considerable portion the cost the power installation has been charged navigation. Boulder Dam the Federal government has fixed charge 1.64 mills for falling water. The operating companies must pay addi- tion all operating expenses, the cost the instal- lation years and transmit the power point consumption. About mills reasonable cost for the power delivered Los Angeles. The preceding comparison manufacturing costs, which led the need for power cost not exceeding one mill per kwhr. enable the electric smelting plant com- pete with coke blast furnace, has neglected the differ- ences costs other than the few items which have been listed. Obviously, group seven small electric furnaces will require more labor, supplies and perhaps more repairs per ton than are required one large blast furnace unit. estimate which was prepared the army engineers for suggested plant near Portland labor 4.89 man-hours per ton was made for naces, each having capacity 5000 seven furnaces the same size the requirements might fall 4.75. the furnaces were increased size 16,000 kw. the labor would fall perhaps 1.75 man-hours per ton. similar labor cost for coke furnace 1000-ton ca- pacity would require men per day men per shift, which nearly twice the organization which modern American furnace would need. This same mates the cost basic pig iron $20.80 per gross ton, $18.60 per net ton. this cost $6.23 per net ton attributed ore, which far the writer has been able determine is, say, almost per ton pig above the ore cost points such Birmingham and With this adjustment the cost ore the equivalent cost pig iron becomes $16.60, which can contrasted with | | j | | e | he | } \ | modification the Tysland- Hole furnace, 7800-kva. unit with the electrodes tandem. far six furnaces this type have been built, all Italy near Milan. The burden introduced through the shaft shown each side. casting side the tandem furnace shown above. Part the current inlet arrangement, the water-cooling installation and the mechanism for charging may seen. Below there shown the furnace jacket, the lower part which cooled water spraying, the casting runner, and part the gas scrubbing arrangement. $10 $12 other centers using conventional nace practice. this estimate for Portland, power charged one mill per kwhr., which less than cost. Electric Manufacture Steel production ingots from scrap the electric furnace common operation and one with which all steel men are familiar. The process simple, rapid and where power and scrap can both had moderate prices, the ingot costs are favorable compared with open-hearth furnace production, For ordinary operation the customary power consump- tion about 600 kwhr. per gross ton production; but where specifications are simple, scrap easily handled and the furnace has abundant power, the operation may speeded and the power consumption reduced between 400 and 450 kwhr. per ton. Under these conditions the conversion cost favorable. the use electric furnace for steel making from scrap the operation almost entirely re-melting with minor amount refining. The steel charge usually con- tains some dirt and oxide which must slagged off but the slag volume small, cheaply made and clean steel high quality can produced from scrap widely varying quality. The metallurgical conditions the hearth are exceptionally good. The production steel from all pig charge, one nearly wholly made pig iron, electric fur- nace horse decidedly different color. such charge the metalloids, carbon, silicon, sulphur, phosphorus, and lesser extent manganese, must removed from the pig iron convert the latter into steel. This involves oxidiz- ing reaction which only obtained rapid- through the use iron ore mill scale and the development oxidiz- ing slag. Power supplied these steel through electrodes made carbonaceous material, either carbon graphite, both which are attacked oxidizing slag iron oxide charged the hearth. The result excessive electrode consumption, and large slag vol- ume reduces speed operation. Thus, there inevitable increase cost. Only rare instances where this operation cannot avoided steel made electric furnace from charge consisting largely wholly pig iron. Where the electric furnace used for pig production, Sweden, the pig made into steel either Bessemer converters open-hearth furnaces. Raw Materials the Pacific Coast this recent publicity concerning the expansion the steel industry the Pacific Coast has revolved around the idea that there are abundant supplies materials but that the fuel supply scant. The proposal has appeared that fuel could replaced power and the Federal projects Grand Coulee, Bonne- ville and Boulder Dam could supply sufficient quantities suitable costs. The map opposite page shows the loca- tions the principal iron ore supplies from the Rocky Mountains west the Pacific Coast. Prospectors have literally tramped grooves over these deposits, and there are reports available all them and many more lesser importance, both for surface prospecting and THE IRON AGE, March 4 underground drilling. The largest deposit probably the one Eagle Mountain Riverside County, Southern California. This owned the Southern Pacific Rail- road and the Government reports indicate reserves more than 50,000,000 tons. this particular instance the pros- pecting work has been meager and practically deep work has been done. The other deposits range size from 2,000,000 3,000,000 tons perhaps 20,000,000 tons, with deposits the last size rare, however. Most the other deposits indicated are small and unimportant almost wholly inaccessible, the case Minarets de- posit which lies high the Sierras elevation more than 10,000 feet. Almost all the iron ores the Western States are the same type and have the same geological history. They are the results the weathering deposit origin- ally consisting largely pyrite—iron sulphide—and the sulphur content today depends upon the extent which the original sulphur has been removed weathering. The Provo, Utah, deposits are about best the west that the sulphur has been thoroughly leached, the iron has been concentrated and the ore now all good commercial grade. west the great majority the ores have not been fully weathered, either because the geology younger the weather conditions less favorable, consequently al- most all these deposits show wherever the prospecting has been carried sufficient depth reach any considerable distance below the surface. From all reports available this almost invariably true. Not only the sulphur high but irregular, and this irregularity always troublesome factor operation. There are many reports iron deposits California, Nevada and Arizona which are said carry about per cent iron. However, past history that entire area has shown without exception that deeper prospecting discloses iron content about per cent, which would all that could maintained regular mining oper- ations. true that this one-tenth higher than the iron the eastern Lake Superior ores, but the latter are low sulphur while the western ores require roasting probable cost over per ton pig iron, possibly few cases they can sometime the future used (as this technique perfected) produce pig iron refined chemical treatment the ladle cost 50c. 60c. per abbreviate all this discussion, therefore, the iron ore situation the Pacific Coast not attractive and does not indicate the any large-scale development. The Pacific Coast states have almost deposits coking coal. Arizona, California, Nevada, Idaho and Oregon have none whatever. Washington there are few small deposits near Tacoma, where dirty coal available which will make strong coke after washing. Utah small area around the Columbia mines and for perhaps miles south thereof produces coal which will make weak coke. northern New Mexico, southwest- ern Colorado and south central Colorado there are coking coals fair quality. Canada there are some coking coals Vancouver Island, the mainland near the coast about 100 miles north Vancouver, and Crows Nest Pass north Butte. The coals Vancouver Island and Crows Nest Pass make fair coke. This brief description the coal resources indicates that there supply close the iron ore resources, except Utah, and that the cost assembling iron and coal one point must inevitably high. The Federal Administration apparently believes electric power can greatly reduce the amount fuel required for the steel industry and that power can had cheaply 32—THE IRON AGE, March 21, 1940 from the Federal projects that the high cost fuel will not serious handicap. The writer raises his weak voice herein that this analysis should subjected considerable modification. Even with electric power, there required considerable quantity coking coal timber (sawdust has been suggested!) for charcoal. The latter appears out the question for big project and only the vicinity Tacoma and Seattle can coal had which will close enough power supply usable. The Federal Government itself has made several reports and estimates pig iron production and one dated March, 1936, coke has been estimated cost between and per ton, which about the figure used the earlier cost comparisons. This the cost for Portland where Bonne- ville power can had low cost. Any other location except near the coal fields will give higher coke costs. The preceding description the iron ore and coal sup- plies indicates that there seem opportunities for the production pig iron and steel through the use electric power costs which can considered cheap com pared with existing competitive operations the Coast. There are ores which are suitable for the Bessemer process, either acid basic, although one small deposit near Portland has fairly high phosphorus content and would make pig iron approaching the grade required for the basic Bessemer process. However, the phosphorus this ore somewhat lower than desirable. The electric furnace might used for making pig iron but the open- hearth furnace should used for steel, and such operation the pig iron immediately comes into competition with cheap scrap. Expansion Pacific Coast Production ERTAINLY the blast furnace economical pro- ducer pig iron far from licked yet, according the data herein. all industrial his- tory and good sense would indicate that iron steel production should centered point where assembly Where then should additional steel industry established? That is, the Government darn hot have one established for commercial reasons for national defense. the mind, least, the map opposite page supplies the would appear that steel plant near raw materials Utah would able deliver its production all points the Coast uniform freight rates and deliv- ered costs that would quite military strategy the issue, then Utah steel-making center would enough from the seacoast free from any probable at- tack hostile planes. Navy Army materials could supplied within hr. and could move with equal facility every one the Pacific Coast ports. The raw materials Utah are ample for century operation, Pacific Coast market requires enough steel support fully integrated and diversified steel-making plant. But course Utah plant would displace existing capacity and workmen Sparrows Point, Birmingham and other sec- tions the country, and the displacement necessarily would predicated some other than free and open com- petition—because many types steel can made exist- ing plants and shipped water the Pacific Coast more cheaply than new Utah plant could make from pig iron (little scrap available) and ship rail. Another culty with the suggestion that Utah ore production would necessarily based conventional blast furnace practice, which would constitute little relief the carking complica- tions Federal power disposal. WELDING ALUMINUM ALLOYS NTENSIVE production tary aircraft imposed upon pean countries recent order keep with the rapid strides made Germany produc tion since the rise the regime has imposed its turn research dependable, economical and rapid Most the European plane manufacturers have adopted American methods stamp ing and forming light alloys because such methods have proved the the other hand, European methods CIAKY type PMCO elec- spot welding operation the plant the Douglas Aircraft Co., Santa Monica, Cal. MARIO SCIAKY Engineer, Anonyme Sciaky methods into ahead of those used in the States. icating these stamp ‘ompleted ship have been United and elec- tric resistance welding aluminum allov sheets the fabric: tures and widely used not only ition secondary struc- parts but also =) ‘ for such vital components ribs, flaps for wing one Italian plant, for example, three-fourths the as- semblies found certain plane mod- coverings. els are means electric the United States, welding until now has been largely spot welding. and the much more costly method riveting has been followed primary situation was due primarily the difficulty structures. obtaining satisfactory welds alumi- 4 THE IRON AGE, March 21, 1940—33 N | 4 > 3 i 4 3 | | num alloy sheets when using conven- tional spot welding equipment. recent months, however, one the resistance welding widely used abroad has been adopted United States. This article will briefly describe the system tance welding developed the French- English Sciaky company Paris, France, which has set American branch manufacture machines Chicago. the short space three months, practically all the leading air- craft manufacturers have purchased one more these machines, and the same period:the Sciaky machine has been tested the Southern fornia Edison Co. Santa Monica, Cal., well the Philadelphia Navy Yard. Satisfactory results are reported from all these plants. Stored Energy Principle Two principles form the basis operation this welding ma- chine: That stored energy and that variable pressure cycle. The principle stored energy consists accumulating certain quantity electrical energy netic form iron core reactor transformer during appreciable period time and discharging that energy much briefer time. For example, the energy stored the reactor 0.1 sec. and discharged the welding circuit 0.01 sec. times shorter, the in- stantaneous power available the welding circuit ten times stronger, less losses the reactor and second- ary circuit. This principle permits then having charged during 0.1 34—THE IRON AGE, March 21, 1940 LEFT TRUCTURAL frame member aluminum alloy being spot welded the Consolidated Air- craft Corp. plant San Diego, Cal., one the new Sciaky machines. BELOW illustrating the ac- cumulation storage energy principle the Sciaky type PMCO electric resistance welder. The reactor charged with electro- magnetic energy from the three- phase mercury arc rectifier. The differential pressure cylinder for the upper electrode pictured the upper right. Maximum current relay Reactor transformer sec. power kva. and dis- charge the secondary circuit power 350 kva. (87% per cent ef- 0.01 sec. Hence the build- claim justified that such ma- chine will the same work with kva. that conventional 350-kva. ma- chine will do, omitting for the moment any considerations quality weld: The power accumulated the re- actor supplied direct current, but the machine whole hooked ordinary three-phase a.c. power line. the current obtained means mercury vapor are rectifier connected, can seen the circuit diagram, with transformer, three phase. The cathode the rectifier and the neutral point the star transformer supply the current. This arrangement gives the further advantage ancing the three phases the power circuit, and consequently the machine kva. capacity, compared the conventional single phase hook up, takes phase power kva. divided This obviously very small power for welding light alloys, which ordinarily require considerable power because their high conductivity, and one can understand the interest the Southern California Edison Co. machine this type, because eliminates disturbances the lines the region Los Angeles where large part the aircraft industry located. The direct current from the rectifier charges the reactor through maxi- mum energy relay which set operate when predetermined amount core the reactor. that point the main switch tripped, and the decaying flux the reactor that sets the high transient weld- ing current. The welding current reaches its peak value instantly and exponential curve relation time overcom- - . Pressure cylinder || | ing the resistance the secondary circuit. The building energy the core follows the same exponen- tial law, there being for any value stored the magnetic circuit. The current the primary before the con- tact opened governed, therefore, adjustable current operated re- lay, having dial gage reading direct- amperes. The amount selected depends upon the thickness the sheets welded. The time con contact pressure v Welding pressure pressure cycle effected automatical- through electro-pneumatic valves which admit air under pressure the hottom side the piston (piston area less area the rod) during the low pressure part the cycle, full pres- piston during this period. The time intervals the variable pressure cycle are determined rheostats acting static time lags, selection being push buttons the side the machine. Secondary (welding) current during the Re-compression (forging) Secondary current the charge magnetically charged core secondary circuit governed serting additional resistance the secondary circuit, thereby using some the energy shortening the time current flow. obvi- ous that the welding current inde- pendent any fluctuations the sup- ply voltage, and that bump occurs the line when the weld actually made, since that instant the primary circuit open. Variable Pressure Cycle The second principle the Sciaky machine the use variable pres- sketch the welding circuit indicates, pressure the electrodes obtained differential air cylinder. curve also reproduced showing tion the variable pressure cycle the welding current throughout the Initially high pressure ap- plied establish perfect contact be- tween the sheets before passing the welding current and prevent “blow- ing electrodes resulting from poor contacts. The pressure then decreased instant before current passes obtain maximum con- tact resistance and hence maximum heat during welding. Immediately after passage the current, the pres- sure increased its former high value with the idea working the metal compensate for the changes caused the temperature rise. This Time ing the same principle. copper electrodes are fully satisfactory machine this type. claimed for this machine the welds are free from cracks. Perhaps the best answer the question weld consistency state that the airplanes that are now action have tens thousands spot welds made with this machine these welds vitally LEFT tion time. small preheating current induced the secondary circuit the reactor while being charged. Welding current rises peak almost instantly following tripping the charging contactor. BELOW POT welding fuel tank Alclad 24S-T duralumin Sciaky machine recently installed the Consolidated During this same low pressure pert- od, the charging the reactor causes low current flow the secondary and this serves preheating cur- rent. When the charge the reactor finished and the discharge effects the weld, the pressure brought and squeezing the hot metal done welded material the initial character- istics, which ordinarily are lessened the heating the pieces. cate, the discharge does not stop sud- denly and the high pressure main- tained during the progressive decreas- ing the current, which maintains the heat during the forging. The variable pressure logated the top arm the ma- chine, and upward and downward movement the upper electrode the air cylinder mentioned and pris- matic slide, fitted roller bearing reduce friction. Controls corporated that prevent flow the welding current unless there fective contact between the electrodes and the work pieces and unless the pressure correctly established in- stant before welding. The machine can operated either with with- which not needed when welding stainless steel. The machine adapt- able for portable welding vided kickless cables are used. Seam welders have also been made, operat- Aircraft plant. ve considering the use plastic for article, the en- gineer usually faced with mass data which highly ing and results difficulty selecting the proper type plastic. Data have recently been prepared the Bakelite Corp., ar- ranged assist determining which plastic will suit particular need best. Plastics are divided into two groups: heated and harden when cooled. They can reheated soften and recooled set almost Such prod- ucts are permanently thermoplastic, and are called following are samples this class: Shellac, cellulose acetate, ethyl cellulose, polystyrene. Products which molding can softened heat and con- after which they cannot softened sufficiently again reform reshape. These are known the “thermoset- ting materials.” products are Phenolics, those obtained combin- ing phenol and those obtained combining urea and formaldehyde. The best known materials and those which enjoy wide use the plastics industry are: 36—THE IRON AGE, March 1940 cellulose acetates, polystyrene. Instead considering these mate- rials property, more instruc- material. The results shown the accompanying table, might called “consumption table.” would desirable, for materials taking the best property any one group. Unfortunately there are variety materials produced each class. For example, all cellulose acetate not the same. The highest tensile strength material the least the most flexible has the low- est tensile strength. So, consider- ing acetates, necessary take what may termed average opti- mistic value what can obtained with one acetate material another. necessary specifically divide them into four divisions, means these divisions cover the properties all the phenolic materials. There are products that come between. How- ever, with the four ranges considered. enough data are available for the pur- pose the table. The table shows the relative tough- ness the various plastics. Also, the relative flexural strengths are shown, the materials being rated from highest lowest from upward. The same thing done strength. which highly shock resistant with gineers when dealing with ask for material higher tensile strength whe