The Iron Age 1940-04-04: Vol 45 Iss 14

virtually all principal railroad systems, find luxurious new streamliners provide you with comfort, pleasure, and save your time. Most these new trains and locomotives are Timken Bearing Equipped. Railroad executives know that Timken Bearings make possible vastly improved passenger and freight service. What partic- ularly pleases railroad men the fact that Timkens cut down waste— cut out hot-boxes—cut out the usefulness locomo- tives—cut operating costs most amazing manner. That means Miles Smiles for the operator well the traveler! THE TIMKEN ROLLER BEARING COMPANY, CANTON, OHIO TIMKEN EQUIPPED NOTICE Look for the trade-mark TIMKEN on every bearing, whether buying new ’ Vy E | A equipment, or replacing a Timken Bearing in your automobile or truck, : the ‘ industrial or farm machinery. That trade-mark is your assurance of quality == ce» & = | ~ ADVERTISEMENT APPEARS THE SATURDAY EVENING POST MARCH 23, NEWSWEEK APRIL That’s what you when you invest modern cost-reducing Warner Swasey Turret Lathes. thousands plants they are aver- aging better than 20% net profit the investment. How? New Warner Swaseys cut cost per piece much 50%, often increase production 100%, reduce end scrap loss. addition, they improve employee relations because they are easier operate and reduce fatigue. Warner Swasey Turret Lathe will pay for itself your plant and earn net profit besides. May prove, figures based your own operation, just what that profit will be? YOU CAN TURN BETTER, FASTER, FOR WARNER SWASEY : J. H. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor News Editor Fditor Emeritus Associate Editors Washington Editors Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany CHARLES Post Milwaukee San Francisco Toronto, Ontario Birmingham Newark, N. J St. Louisa TURNER, Buffalo DIX, Manager Reader Service ADVERTISING STAFF B. L. Herman, Chilton Bldg., Phila. H. K. Hottenstein, 1012 Otis Bldg., Chicago H. E. Leonard, 239 W. 39th St.. New York — Peirce Lewis. 7310 Woodward Ave., Detroit C. H. Ober. 239 W. 39th St., New York W. B._ Robinson 9 W. J. Fitzgerald 428 Park Bidg., Pitts. D. C. Warren, P. O. Box 81, Hartford, Conn. Don F. Harner. 1595 Pacific Avenue, Long Beach, Cal. Member, Audit Bureau of Circulations Member, Associated Business Tapers Indexed in the Industrial Arts Index. Published every Thursday. Subserip- tion Vrice: United States and Tos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 a year. Single copy, 25 cents. Annual Num- her $1.00. Cable Address, ‘“‘lroenage. Owned and Published by CHILTON COMPANY (Incorporated) Editorial and Executive Offices 239 West 39th St., Publication Office Chestnut and 56th Sts., Philadelphia, Pa., U.S.A. New York, N. Y., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY Machinery Editor Art Editor Metallurgical Editor Contents April 1940 Take Out the Pins Continuous Casting Percussive Welding Metal Finishing Costs Rolling Sheets and Strip Using Lamps for Industrial Heating Temper Cracks High-Speed Steels the Assembly Line Washington News THE NEWS BRIEF Statistics Metal Working Activity Weekly Ingot Operating Rates Rate Activity Capital Goods Plant Expansion and Equipment Buying Free Industrial Literature Just Between Two Products Advertised Index Advertisers Copyright, 1940, by Chilton Company (Inc.) 112 116 142 178 ~ afi a 40 | the right reproduced unretouched photograph Welded Steel Machine Base produced Mahon for the Potts Machine Co., Jackson, Mich. Above shown the Fox Five-Way Drilling Ma- chine for which the base was built. Greater Strength and BETTER APPEARANCE Fabrication Welded Steel Machine Frames and Bases art which skill and workmanship show immediately proper equipment and highly efficient craftsmen are essential meet the demands progressive machine builders today. The Mahon Company, realizing the importance finished appearance, well accuracy, this field, set out devise fabricating methods which would assure not only accuracy dimension, but the utmost fine workmanship—a smoothness and trueness finished appearance unsurpassed anywhere. you demand machine bases exceptionally fine finished ap- pearance upon which you will proud place your company’s name, send your blue prints Mahon for quotations. THE MAHON COMPANY DETROIT, MICHIGAN Manufacturers Machine Frames and Bases and Many Other Steel Products | ; q Tie : 7 5 : 4 28—THE IRON AGE, April 1940 ... THE IRON AGE ... APRIL 1940 ESTABLISHED 1855 Vol. 145, No. Take Out the Pins ALES resistance luxury that most can't afford. Like taxes, something that the basis this principle, makers machinery and suppliers service our industry try make easy possible for the customer put the product into use. Sell- ing, fact, really begins after the sale completed. That, least, the theory. Every sales manager our industry will subscribe and tell you that follows practice. But fear that some are deceiving ourselves this matter. Last week, for example, came across sale that was unsold after was sold, simply because the concern that made and merchandised the product had unwittingly copied the strategy the shirt industry. The shirt industry one America's favored industries. Society has ruled that men shall wear shirts. So, times, have buy new ones. The shirt merchandisers have developed the most ingenious and formidable obstacle prevent the easy application use their product. Men hate buy new shirts because there are many pins them. the inventive genius that has been spent the shirtmakers devising new ways conceal pins could put constructive and useful purposes, instead being applied building sales resistance, America might well much further along the path recovery. What has all this with iron and steel and machinery the capital goods industry? has great deal with it, learned from the case the machinery maker whose product was unsold after the sale was made. This machine was sold its merits. was good machine that really fitted the cus- requirements closely properly sized shirt would have fitted his anatomy. But the machinery maker put too many pins the package. happened that this was the first machine its make enter this particular plant. The people there were not familiar with it. And for shipment, the maker had acted upon the presumption that the purchaser was familiar with the product its maker. The instruction sheet was intelligible income tax blank. the time that the puzzle was solved and the machine was ready operate with parts left over, the plant people were frame mind condemn anything that came out it. Pins shirts. Are there any yours? 2 i 4 BAR the skill steelmakers For many years Inland has been lead- ing producer bumper bars, one the most intricate and exacting types bars rolled. The steel must clean and sound the size and shape must accurate. Although hot rolled product, un- usual degree surface smoothness required for plating, assuring perma- nent finish. TIN PLATE GARS PLATES FLOOR PLATES The same degree skill evidenced the making bumper bars practiced throughout the Inland Bar Department. When you buy hot rolled bars from Inland, you secure product that will meet the specifications required speed your production and reduce your shop costs. When you seek high quality bar stock, come Inland. STRUCTURALS RAILS TRACK ACCESSORIES REINFORCING BARS Dearborn St., CHICAGO District Offices: MILWAUKEE ST. PAUL ST. LOUIS KANSAS CITY CINCINNATI TCHED cross-section, actual size, brass billet (62.5 Cu, Pb, Zn) continuously cast the Junghans machine. ° ° mitting jump molten metal strip, sonable, apparently simple, that the past 100 have brought forth from tions several basic ideas, most Which were doomed burial patent office, few which actually experienced the trial fire—and for the most part found wanting. quietly and for the most part secretly, there resurgence activ itv. Seovill Co. compara tively simple German unit each week, week and week out, has excellently designed mold which shows attractive possibil ities with Eldred’s turns pointed, part, toward conver sion small plants; both the Alu Smelting Refining Co. have com Pittsburgh steel maker recently spent small fortune the strip casting process; and Hazelett has vised new high speed strip casting unit that will hit over 500 per LIPPERT Metallurgical Editor, The Age with non-ferrous metals with alloy steel. exactly what are these esses? How they operate and how they perform? there general relationship, and what? whole technique continuous casting the same time complex, and deliberately beclouded. various processes are, however, the first time brought into the open the following pages, and effort made orientate the practice continuous casting today—to toward future possibilities. THE IRON AGE, April 4] a 4 , » % te |_| ACING across the yard his St. Pancras factory England almost 100 years ago, the youth- ful Henry Bessemer finally got some unfrozen metal pair horizontal rolls. (See sketch and Bessemer’s own record, next week.) not only ob- tained some ragged strips iron, but sold himself the idea that such was the way produce steel—no ingot mold, soaking pits, breakdown roughing rolls; just one simple in- expensive machine transform liquid metal semi-finished strip sheet. Norton and Hodgson idea almost unchanged (see Norton’s diary, week) around the turn the century—they were equally enthusiastic and equally un- successful establishing commercial operation. contemporary Norton and Hodgson, Swede, Worcester, Mass., Johan Trotz, was the first intelligently swing away from the molten metal into moving mold, two horizontal rotating rolls, spaced form mold chamber, the speed rotation being the same the ingot that there relative motion be- tween the two. Trotz kept his mold stationary and metal through it, and his series patents (648,091; 705,721; 770,130; 894,410) easily understood record how encountered various difficulties and progressively groped solutions. (See two sketches opposite page. Within the past decade, and today, Hazelett has injected new life the Bessemer-Norton-Hodgson his similar casting-rolling mill (see sketch and description next but recently has shifted variation the horizontal-roll scheme, variation which essentially casting unit very high speed. The Trotz idea pouring molten metal through tionary mold has splayed Williams, the Junghans, the Poland, the Eldred and related processes. All variations each the two basic ideas—moving mold and station- ary mold—could harshly judged being identical, the volved just bunch Micawbers. fact, today’s machines might age, ultra-suspicious German inventor, is a member of the mechanically gifted Junghans family which built the great watch and clock industry in the Black Forest. Irving Rossi, Wall Street, New York, owns per cent the continuous casting process and takes care licens- ing throughout the world. Principal patents are Nos. 2,135,183-4. Sieg- fried’s brother developed cessful mechanical anti-aircraft shell fuse for the German army, which recently was purchased by the United States and is now standard for mm. sheils. 32—THE IRON AGE, April 1940 compared with Bessemer’s sketch Trotz’s original sketch, and the conclusion reached that little sensi- ble progress has been made—that to- day’s machines are cursed with the deficiencies their predecessors, uncertain operation, low output, some- times good metal and sometimes very poor metal. However, progress undeniably has been made. There has accumulated great fund knowledge how operate the machines and how direct and control the thermal exchange be- tween molten metal and Williams, for instance, has overcome the general fear (of explosions) getting molten metal near water, and has devised molds with extremely thin walls and literally scours the heat off the one side with thin films water high speed. Junghans mold cyclically and depends tive inertia mold and metal mini- mize skin fractures cast billet. Eldred and Poland design their graphite mold and cooling system secure unblemished skin and desirable metal structure. And Hazelett employs large inexpensive roll shell and light topping roll obtain rapid cooling and high speed. Perhaps all these refinements seem mean little, but certainly the end they will determine the broad commer- cial acceptance these methods producing metals. apparently in- significant detail may well the crux the whole problem any one ma- chine. Certainly, many the present- day metal production machines are just such apparently insig- nificant details. The continuous mill, for instance, has slight camber the rolls, and this transforms the series roll stands from ineffectual masses metal the highly efficient sheet rolling unit is. Out all the welter patents there have been cast up, say, eight nine distinct processes, these particular ones rating detailed attention being far advanced experimentally down- right commercial successes. They are: INGOT BILLET UNITS: (1) process (2) Williams process Eldred process (4) American Smelting Refin- ing Co. process. (Poland) Aluminum Co. America process. All others, such Cramp- ton, Goss, etc. STRIP SHEET UNITS: (1) Hazelett casting-rolling mill Hazelett strip-casting mill (3) All others, such Merle process. scribe the strip and sheet casting units graphs immediately following are con- cerned with the ingot and billet casting units. With the descriptions hand, even the casual reader will note that for all the there definite consanguinity. the billet and ingot casting units par- ticularly, the same casual reader might prone attach too little importance the nuances design. But, the ingot casting units definite variations performance—in speed, control, length uninter- rupted run, quality metal and metal surface, ete. Junghans Scovill the ingot and billet casting units, the Williams process undoubtedly has the most data hand metals. the other hand, the Jung- hans machine established abroad for variety non-ferrous metals and has one cessful installation this country, the Scovill Waterbury, Conn, There has been volved the development continu- ous casting Siegfried Rather, and number assistants have for years patiently ingly exhausted practically every vari- ation mold and pouring speed, tem- perature, and cooling meticulously listed Junghans little notebooks. various com- mercial mills are the result all these efforts, still being subject re- finement and change, course change lift the speed, pierced and/or composite billets, and continuous casting various ferrous alloys. There Junghans unit working continuously day and day out the schaft, Bitterfield, Germany, alu- minum alloys. Either billets lar ingots are continuously cast. the plant Ulm, Germany, two units are operating brass and one unit aluminum alloys. One the brass machines turns out 8-in. diameter rounds for extrusion into condenser tubing. The alloy mostly aluminum-brass, mental analysis which previously had heen expensively cast individual process. The other brass machine casts cartridge alloy ingot form, i 4 | > 4 ‘=e J q 4 J ~ hy 1 f measuring 24x4 in. metal. the plant Wintershall A.G., Kassel, Germany, machine casts magnesium alloys, and Junghans himself has unit Stuttgart, Ger- many, turning out aluminum-alloy in- gots for the German the same plant, Junghans’ newest ma- chine not only continuously casts in- gots but replaces the pinch rolls with heavy reducing rolls and thereby gives the ingot heavy reduction while still hot. machine has just been built and soon will operation the plant James Booth, Ltd., Birm- ingham, England, for casting alumi- eter, for subsequent tubes. The only other Junghans that which has operated for over year Scovill Mfg. Co. Results date have been eminently satisfactory —over 60,000,000 Ib. brass has al- ready passed continuously through the current schedules call for more than 1,250,000 metal per week off this one ma- stepped-up far above this level—but facilities are not sufficient supply molten metal continuously such pace; nor are salesmen currently able dispose finished rod, wire and tubing faster rate. The brass industry cally different method casting, such the Junghans machine. two decades hand casting, un- changed since antiquity, was nique’ which has kept the mind open all new Valley brass companies, family affairs and highly secretive, were to, say, 1916-18 pretty much the mercy of even more secretive father-son guilds brass casters. Head were not employees of the brass .compa- nies, but rather contracted to supply so many ingots, and were power unto themselves hire and fire assistants. witch concocting brew had nothing brass caster, each whom specialized plied war demands for brass found the companies hamstrung by the tight hier- archy of casters, and there resulted dra- war-time labor and production hysteria. Metallurgists were hired brass compositions ; pyrometers developed to establish optimum pouring tempera- tures; operators scrapped conventional small individual molds multiple molds and ing; small crucible melting units gave large oil-fired furnaces, which turn were scrapped make way for low-voltage (18 v.) “eontact resistance” furnaces, these latter being scrapped sometimes on delivery as the Ajax induction furnace rapidly came the fore highly cient and dependable melting Compressed gas for cover , 4 Stopper 4 Water Steam pressure nozzle water (heated for electrically OHAN TROTZ, around the turn the century, conceived the continuous casting ingots shown the right, and few years later proposed the alternate scheme shown above. Many years later Poland and Lindner proposed the arrangement shown below, modification which currently used Receptacle for molten metal Cooling Jacket Water for cooling jacket Hopper for metal cooling Joint Space for metal and resist pressure tube Tapered mold (graphite etc. THE IRON AGE, April 1940—33 \ Pinch rolls Junghans machine is_ interesting enough warrant degree ramifi- Heating Insulated About eight years ago exper- | | --- gas seal imented extensively with the Hazelett molten metal reservoir cast between two rolls and though some segregation the low- melting point Physically the slight segregation was bar numerous applications, but Space for electrical Mold re ciprocates | transformers, desired speed reservoir tion, however, was the slow speed, Billet feed and mold reciprocating speed not being sufficiently promising ingot casting equipment. duction was the continuous casting billet driven feed rounds the Eldred process, from lurgically beautiful metal was turned out, but here again the output was During cutting off operation saw quite small—at best Scovill could get clamped descending billet only several hundred pounds metal PLAN VIEW Saw per hour. heard Junghans process. Copies the patents were secured and studied conclusion that the drawings were detailed sketch above shows the arrangement parts and mode oper likely not operate satisfactorily. None ation the Junghans machine, number which are operation Ger- the less, Scovill sent two engineers many and one each England and the United States. the Wieland plant few miles outside Ulm, Germany. What they found Forming chamber there was Junghans machine identi cal with the patent drawings, operat carborundum, etc.) ing hr. day, turning out for the which were subsequently rolled for fabrication into shell casings. agreement was reached—Sieg fried Junghans would build machine for Scovill, send crew men Waterbury erect it, acceptance continuous seven-day run without shut down, casting minimum 7700 per hr. diameter billets high-speed screw machine brass. Sco vill engineers expected days Water prays the last bolt and yelled for metal. then there was more trouble the unit than trouble with ANY years ago Eldred conceived the continuous casting rods shown above. Later, production units showed some modification, particularly The construction the Junghans the location cooling elements. machine both compact and simple, 34—THE IRON AGE, April 1940 | ~ ‘ / ; / POS) 4 shown the sketch the opposite page and the photos page 37. One- half ton ladles brass are brought from series Ajax melting fur- naces and bottom poured sealed holding furnace shown the sketch. Oxygen-free gas kept above the metal the holding furnace un- der some pressure. This gas comes from small gasoline engine which consumes about gal. gasoline per day. The engine operates gas com- pressor which compresses its own ex- haust gas, which then cooled and scrubbed and passes from which valved the hold- ing furnace. Occasional adjustment this valve changes the rate de- livery the molten metal mold. U-tube extends below the metal surface the holding furnace, and carries the metal over into feeding chamber, whence passes down into the mold means gravity feed through the bottom. Note that there are three separations metal from surface dross—first when the metal passes through the bottom the ladle into the holding furnace, second the metal passes from holding furnace the feeding chamber, and third the metal drops down into the course, any floating impurities should get through they would float top the constant molten pool the mold and then could skimmed off. Note also that the several tubes car- rying the molten metal—from holding furnace chamber, and from chamber mold—are heated electrically rect resistance, prevent metal freez ing the inner walls. The mold itself ordinary com mercial drawn copper tubing, with about wall thickness; can square, various rectangles. Any these molds can placed the same water jacket, pack seal being used top and bottom. The cooling arrange- tempt feed cooling water through under great pressure, nor the wa- ter jacket altered the cross- section changes. The water flow changed, course. The particularly conspicuous char acteristic the Junghans machine the automatic movement the entire mold, water jacket and all. cam arrangement, the mold moves down the same speed the emerging billet, through distance about 134 and then snaps back quickly original position, the snap-back speed being about three times the speed the billet. The function the move- ment present constant chang ing section the mold wall the molten metal, and also because rela- tive inertia minimize skin ruptures the billet. Junghans has elaborate tables set the amplitude the mold cycle and speed snap-back for dif- ferent types metal, cross-section billet, speed, The operator oc- casionally sprays the top the molten metal with oil, which because the surface miniscus runs the wall and part burnt and part carried down LLOY steel billet emerging from the Williams continuous cast- ing machine speed about ft. per min. The cooled section (center) and the twist the billet resulted from turning off cool- ing sprays and stopping the movement or- der take this natural color pho- tograph. lubricate the wall surface. Many different types oil will work satis- which synthesized from turnips. It’s not very good, but works. The billet red comes from the mold, and cooled means water sprays. diameter billet comes out the rate in. per min. but much higher speeds are deemed possible, desired and molten metal available. lower plat- form operator handles cut off saw, Which brought into place and moves down with the billet trav- erses. The severed billet drops off and passes down chute carried extrusion press. Occasional chips from the saw the labora- tory for analysis, and the remainder collected another chute and passes back the melting furnaces. Obvi- ously scrap losses are negligible. The temperature the metal (brass) the mold about 1750 deg. F., which about 135 deg. lower than the temperature metal poured into conventional ingot molds. There scarring erosion the copper mold. addition the three separations metal from the surface dross, the large holding furnace assures mixing. and the analysis the billets pro- duced said more constant and easily controlled than conventional practice. Metallurgically, the metal produced good and often better than that turned out conventional ingot pouring. About any distribu- tion crystal size and direction can secured varying the cooling, both the and the sprays the exit end the mold. might pointed out that ingots from the Junghans machine usually have sizable cross-section, apposed handled some the other machines, particularly Eldred’s unit. The Jung- THE IRON AGE, April 1940—35 hans ingot also often blemished barely visible surface rings (probably due the mold although the rings are only skin deep and cer- tainly not carry into the metal. still, possible that the rings might give rise some consumer re- sistance the ingots were sold un-scalped. Only several men are required operate the Junghans machine—and molten metal, the thorn moving cycli- cally with the mold. Junghans himself fully confident that his unit can easily continuously cast carbon and alloy steels, just soon can get around doing some serious work that problem. Williams Latrobe Undoubtedly the greatest amount continuous casting equipment, ready for experimental run steel. The piping the mold (center) for water cooling, and below may seen several the sizing rolls. Speed about ft. per min. these have little do. becomes quite job stay awake, what with the heat, the monotonous movement the mold, and the constant low noise the reducing gears the one small motor operating the entire unit. Junghans currently experimenting with variation his machine con- tinuously cast composite metals. Also, tubes have been experimentally cast, the set-up for this purpose having down through the 36—THE IRON AGE, April 1940 Edward Williams, president Vul- can Mold Iron Co., Latrobe, Pa., the continuous casting operations be- ing carried out for well over decade personal company, the Williams Engineering The Williams patents are concerned principally with and method mold cooling. Two patents are existence 2,187,720). and third has been allowed and will issued about three months—it deals with mold fourth patent pending. The Williams process accomplishes the necessary heat removal provid- ing very thin mold wall high con- material (commercial drawn which heat can rapidly pass from the ingot, and removing this heat ex- tremely rapidly from the outside the mold wall means water other cooling fluid passed high ve- locity along the surface. removing the heat rapidly from the outer surface the mold wall, high temperature gradient produced the mold wall, which permits fast removal the heat from the ingot. claimed that this instantaneously freezes the molten metal into skin which shrinks away from frictional resistance and ciently strong prevent fracturing moved along the mold wall. The cooling water mold passes through passages which have very small clearance, the velocity be- ing quite high. has been found that relatively small amount water (such gal. per minute mold sq. in. cross-section) sufficient satisfactorily remove the heat from feet per The temperature rise the water, under these conditions, only about deg. Since the cient the conductivity the metal being poured will permit heat re- moved from certain maximum rate, stated that the speed heat transfer through the mold wall and removal therefrom does not exceed this rate. The Williams mold does not move. the billet ingot emerges from the bottom passes through series sizing rolls that prevent bulging the walls ferrostatic pressure from, the molten interior. surround these sizing rolls ingot quite cool when gets down the pinch rolls. The entire setup may seen the color photo page (which shows the exit, be- low), and the other photo this page (which shows the top, pouring). liams frequently uses mold lubrication increase speed casting. The lu- bricant introduced the top along the mold wall, the quantity being con- trolled the speed the pinch rolls drawing the continuous billet out. Williams has cast only experimental lengths, but for plans cut off the billets into specific lengths means saw (as does lance for high alloy steels. Most the | experimental steel casting 6-in. rounds and measuring in. The steel being cast the photo page had quite high alloy content—the surface was somewhat blistered, but not badly so. Stainless steel likewise has frequently been cast experimentally. struc- ture for the most part tory, and the steel has been rolled out satisfactory commercial grade rod and strip. far the Williams machine has been given steady trial over long run steel. unit cur rently operating copper alloys the plant Bridgeport Brass Co., and preliminary reports indicate fairly sat- isfactory performance. For his process, continuously cast- ing steel, Williams claims the steel in- dustry has means eliminating piping and segregation with conse- quent great improvement metal Also control the solidifica tion (and structure) the ingot provided the cooling sprays (or tempering chamber). Williams also visualizes the continuous casting semi-finished shapes, for instance and composite metals, feeding ingot already made into mold around which molten metal poured; and tubing, providing stationary mandrel the forming mold. already mentioned, Williams’ patent activities have been directed primarily toward mold method cooling, believing that for steel particularly the heat exchange must necessarily fast controlled. The copper ently stands well under the temper- handling steel, the same been used many times pouring perimental heats, with apparent de- Williams has demonstrated the rapid heat transfer the mold wall very dramatic scratch has been made the wall and filled with solder, after which heat steel poured through the mold. Later examination has shown the solder still intact the scratch. Despite the many experimental steel heats poured Williams, the devel- opment his machine seems now the pattern set other machines—that is, finding its first serious commercial trial fer- rous metals, witness the present stallation Bridgeport Brass Co. Perhaps later the machine will shift from the non-ferrous field serious Junghans machine (top view) casting brass billets continuously Scovill Mfg. Co., the speed being about ft. per min. One the two holding furnaces (left) feeds molten metal into the small reservoir (center) from which passes gravity feed into the water-cooled mold (lower center). commercial trial for great deal additional experimenta- makers carbon steel who habitu- tion will necessary before such ally handle small heats have shown in- procedure could established terest the process. However, more competitive metallurgical and com makers high alloy steels and cer tain types stainless steels may see Eldred, Poland, Al. this process Whereas both the Junghans and present high scrap losses molds are metallic, with con- and more flexible method han- sequent rapid thermal exchange, the dling small tonnage orders. so, system first proposed about Junghans machine Scovill, showing cut-off equipment below floor level. The brass billet (upper center, with steam coming from surface) cut into specific the saw (center), and these lengths drop into chute. : ) Kary ° ° ° refined employs forming chamber dense graphite (radio excellent), carborun- dum other material resistant heat and corrosion. Around adjoining this forming chamber cooling chamber through which water cir- culated, and after the continuously cast rod billet leaves the machine may further cooled means sprays, this latter being typical all proc- esses. The patent drawing Eldred’s machine reproduced page 34, this particular set-up showing three form- ing chambers drawing from the one furnace. Various features the dred machine are covered patents 1,868,099; 2,048,733; 2,048,734; and 2,135,465, and licensing under the direction the Continuous Casting Corp., New York. ago steadily time Byron The use the particular die mate- rial, the design the forming die (which varied for different metals, temperature conditions, etc.), and loca- tion and design the water cooling system are all features the Eldred machine differing from the two already regards thermal changes taking place forming chamber (die), sents some rather recondite observa- tions. For instance, one many claims his patent specifications deals with “method casting metal shapes which consists continuously supply- ing molten metal open ended forming chamber, having congealed metal the lower portion, congealing additional metal thereabove with- drawing heat solely through the congealed metal, re- moving the congealed metal and cool ing the forming chamber maintain constant described. gradient therein.’ Eldred has explained that his proc- ess separates the removal super-heat and latent heat progressively quan- titative timed relationship. However. the exact action what may, there denying that the Eldred process turns out beautiful metal. The crystal- line structure can controlled, and usually the rods billets are turned Byron Eldred, who and looks 50, retiring individual and little the temperamental side, could perhaps designated professional inventor, but certainly inventor considerable re- nown. Among his many inventions are Dumet, the low expansion alloy used for lead-in wire incandescent lamps, bought 1916 General Electric for what was then supposed the highest price ever paid for single invention; also, glycol, purchased Union Carbide Carbon Corp., and now marketed Pres- tone; also, production basic material for manufacture novocaine during the World War; also, the optical light slit, now used universally sound recording euipment. 38—THE IRON AGE, April 1940 temperature out with orientated the lon gitudinal direction, The crystals quite enormous size, and one instance copper rod with single crystal ft. long. The metal structure like throughout- this demonstrated the mechanical working the metal, which throughout entire The metal gas-free and very dense (copper density compared with the usual 8.934), and frequently has exceptional mechanical properties cast. Also, the metal surface quite smooth, and scalping (as cross-section. the prior art) not necessary before additional hot cold working. unit smaller than, say, the Junghans Williams machines. rod, for instance, might cast the rate less than foot minute. This might anticipated inspection the machine design and the die mate rial, what with the likely thermal exchange for But, really this slowness pro that partly the metallurgical metal. Eldred attempts increase the output particular unit putting multiple forming dies one furnace, excellence the but for that matter the slowness the earliest Eldred machines, shown here cast ing copper rod (34 tol in. diameter) the plant Bridge port Brass Co. 1933. Speed was for 24-hr. runs. Occasionally the operator looped cast rod form the long coil the bottom. judged bothersome- cation the machine being predicated the quality prod uct, excellence surface finish, and ease operation the machine. One earliest experimen tal machines was Bridgeport Brass Co. 1932, casting 1-in. single copper rod out the bottom, shown the photo this page. much larger machine was installed experi mentally 1934 Scovill Mfg. and, shown the opposite page. nickel) continuously out the side the furnace, rather than out the bot the moment, Eldred machine Operating commercially, last vear the Aluminum Co. Amer- ica secured Eldred license, probably avoid interference with their par ticular process continuous casting. believes that his method has attractive future large plants pro ducing great quantities commercial metal, although particularly believes that many machines may find wide usage converting units plants. For instance, machine with one operator could work continuously yard converting non-ferrous scrap known analysis which would salable the open market. For the most part, Eldred sees his machine producer smaller although. q size rods simple shapes, say less than in. diameter, opposed the sizable cross-sections handled Junghans and Williams machines. Eldred machine does not use die bricant, and most the work has been done with non-ferrous metals. But, the casting ferrous metals would appear involve insurmountable difficul- ties, view the excellent heat sistance the graphite die used. the plant the American Smelt ing Refining Co., Rahway, continuous casting machine has been operation for year and half, stead- ily turning out oxygen-free phorized) copper billet, in. diam- eter, which sawed into 50-in. lengths for sale the open market. Most this material: (after scalping) has been going piercing machines for the pro- ingly extremely satisfied with this mode production, opposed con ventional casting practice, and claims that the billets continuously cast are preferable because minimization surface defects the finished tubing, the elimination porosity the metal, high density the metal, and the close dimensional nothing but round billets commercially, but has several times that consideration was being given the continuous casting simple shapes. operates under the Poland-Lindner pat ent (2,136,394), sketch which shown page 33. patent deals with the continuous casting and copper-base alloys, and although various designs forming chamber and cooling chamber are detailed, the reader will note from the sketch that the Poland and Eldred designs show the thermal transfer the mold cham ber, Poland-Lindner specify “cooling the metal extraction heat through the die walls and continuously with- drawing the solidified metal not withdrawing the heat down the previ ously congealed The mold material “refractory, heat conduct ing material, which and usually graphite extreme density boron carbide (B,C), both which should easily machinable and take very smooth finish. machine. The die itself may about in. length and the speed casting not very high, say the order in. ft. per min. for the 3-in. diameter billet. The Aluminum Co. America has cast continuously commercial pro- duction for some time several its plants, one unit being New Ken- sington, Pa. The company has dred license, but the machine its own design. The process changed several times, and the com- pany does not permit visitors watch operate. the writer were guess, how- ever, would suspect that metal tionary. Most the production perhaps and rounds, and quite sizable slab ingots measuring perhaps the speed varying from min. Casting intermittent that one length cast after which pouring stopped until the ingot removed make way for another stead using pinch rolls the ingot moves out the mold and down through cooling sprays hydraulic elevator. Aluminum none too easy passes through mushy stage, which results some folding-in the sur- essary. the roundup continuous casting machines, wherein the mold wall remains stationary relation the metal flow, about completed. An- other patent this general type which (2,145,416) which relates the continuous casting rods, tubes, likewise has created some in- terest. Also, Norman Goss, Cold Metal Process Co., has experimented with mold wherein graphite lubri- ONTINUOUS 6-in. diaméter billet this case the plant Scovill Mfg. Co., late 1934. This experimental Eldred ma- chine cast out the side the furnace speed several inches per minute. Most machines cast from the bottom. cant forced through apertures the mold wall during pouring, the ob- ject being eliminate sticking and fracturing the ingot wall. certain amount experimenting has been done with this machine, and the results have been moderately encouraging. Also, there has been considerable interest this type production the U.S.S.R., and the Ter. Akopow method cate No. 29,000) suggests pouring metal into ingot mold, which con sists individual half forms which automatically open and close. This similar the Grenville Mellon system the Continuous Casting Co. Gar- wood, which was given un- successful trial during the World War 3-in. diameter and smaller bars brass and other non-ferrous metals. the moment, the International Nickel Co. Canada believed experimenting with process this general type. Tamman and Moritz (Zeitschrift fiir Metallkunde, 1935, 115) suggested the continuous produc- tion thin wire not under 0.004 in. diameter chilling fluid metal, but anticipated inherent difficulties main- taining the nozzle. And Keller has sug- gested (Zeitschrift Metallkunde, 1933, 15, XII, 115-226) the production sheet metal where the chilled There have been still other suggestions advanced, but most them never even approached actual trial and many are quite hazy details. Ed. Note:—Next week this article will concluded with review recent machines for continuously casting strip, with particular attention given new high speed unit for alloy steels. ™ 4a 4 . OME recent developments have been made the percussive weld- ing process which increase the range usefulness this technique. Percussive welding defined re- sistance butt welding process wherein electric energy suddenly discharged across the contact areas welded and hammer-like blow applied si- multaneously with immediately fol- lowing the electric discharge. * The need for process such the percussive method first arose electrical industry the manufacture lead-in wires for mercury rec- where was desired join wires made dissimilar metals, where was necessary put platinum tips nickel rods, join two highly conductive metals like copper and aluminum. The latest commercial units permit welding this character, welding machine with dial feed, made the Taylor-Winfield Corp. for joining in. diameter tube disk, both made SAE 1010 steel. These are the steel reinforcing pieces rubber engine mount. the left the condenser bank for storing the charge for producing high amperage arc instant before the parts are brought together under impact. The cycle completely automatic, and output the rate assemblies per min. per hr. Operating guards are not place. 40—THE IRON AGE, April 1940 covering areas sq. in. pro- vided this area concentrated, such the form rod (0.564 in. maxi- mum diameter in, square). process percussion welders, are being built the Taylor-Winfield Corp., Warren, Ohio. However, the patents are owned the Vanco Prod- ucts Co. Detroit, from whom li- cense use the process must first obtained before the equipment practice. The particular patent involved No. 2,159,916, Alfred Vang, Detroit, May 23, 1939, and assigned the Vanco Prod- Co., firm formed Mr. financial backers during the course the development. Later agreement was entered into with Taylor-W infield whereby the Vanco company agreed work with exclusively the de- velopment production equipment for practicing the process. Taylor-Winfield has introduced number refinements design. The first machine produced was high pro- duction, special-purpose type with dial feed. had output com- pleted pieces minute. Since then been introduced, which will scribed detail later. machines have not been available, although the been use for over years. 1913, the research laboratories Westing- house Electric Mfg. Co., obtained patent No. 1,066,468 process percussive welding which the energy stored high capacity condenser discharged through the points welded when they are brought into 3 | | Metals may joined, despite great differences mass and thermal conductivity. Consequently, the automobile and other industries ave finding this technique particular value obtaining welds. contact with force considerable enough obtain forging effect. Chubb this technique the welding lead wires running size from Nos. gage and employed con- densers 1200 1400 microtarads amount energy relative the size the work. brought together initially with point contact, abutting the chisel edges nipped wires right angles each other. Impact was provided the weight falling carriage and chuck for one the wires joined. The voltage used—about 200 volts start —was low, however, that current did not flow between the metals until they were brought into actual contact the instant impact. The sudden release energy caused small plosion and actually vaporized some the metal, fact that explains how sound welds were obtained alumi num, since oxidation the surfaces was prevented the vapor shield. oscillatory discharge the condenser was produced with current peak about 500 amp. the top the first half High Voltage Used The Vanco process electric per cussive welding, although employing essentially the same elements Chubb machine, works entirely different principle, and the values voltage and current are markedly ferent. Mr. Vang conceived his idea after observing the accidental welds that are produced within contactors and switchgear result arcing when high voltage electric lines are short-circuited. the Vanco process, the current used sufficiently high voltage (4000 5000 volts) that are formed between the two metals being welded the brief interval be- fore they actually come into contact with hammer-like blow, and the heat from the arc that brings the sur faces molten state rather than the resistance current flow the con tact points surfaces. Furthermore, the Vanco process the surfaces welded are ably flat such that surface-to-sur- face contact made between the met ENERAL pur- pose percus- sive welding ma- chine suitable for metals rod form, such the welding high speed steel drill rod carbon steel shank with- out flash. The guards are shown when load- ing the dies. number safety interlocks have been provided assure absolute safety the operator when the high voltage arc discharged. FRANK OLIVER Associate Editor, The lron Age als. actual practice, one component held stationary fixture and the other held movable slide re- tracted against spring air pressure. Upon releasing trigger, one piece moves toward the other rapidly, and when reaches distance depending upon the voltage, the breaks down across the gap and less than thou- sandth second later the two sur- faces are brought together while they are still molten. During the arc, the current oscillates positive and nega- THE IRON AGE, April Bee ° ° ° Resistance Step-up transformer a.c. /mpedance Moving Work holding dies Condenser bank CHEMATIC diagram the electrical hookup for producing per- cussive welds the Vanco process. Line voltage first stepped the iron core transformer, then rectified vacuum tube unit for charging the condenser. Discharge the condenser takes place less than thousandth second when the two ends the work are brought close enough for the air gap break down. Contact under impact immediately follows. : — ¥ , i typical Vanco welds, both magnified 250 diameters. the left, steel (left) shown joined copper (right). the right, copper shown joined copper. The growth new crystals across the weld line can seen. tive, decreasing amplitude rate depending the resistance the cir- cuit, which includes the varying re- sistance the joint itself. get the greatest heating from the oscillatory current flow, necessary not have the metals come into con- tact until after the end one com- plete cycle, because the spark jumps from point the positive electrode large surface the negative elec- trode and then reverses itself. Hence least one full cycle must com- pleted make each work element negative electrode that the entire surface each electrode becomes mol- ten. The ideal time for the physical contact the the second cycle that slightly greater depth 42—THE IRON AGE, April 1940 practice, balance must struck be- tween speed approach the mov- able portion the work and the fre- quency the oscillatory wave set the constants the circuit. Flash Produced the other hand, the force im- pact must not such create flash metal upset the ends the work. fact, the dial feed type machine referred was built not only weld disk and tube SAE 1010 steel very fast time, but also the job without producing flash. any event, flash minimum, since only the surface the metal brought the molten state and truly surface weld produced. Heat-treat- metals therefore can welded without disturbing the physical prop erties the metal right the weld. The schematic wiring dicates the method producing such arc from ordinary 110-volt, 60- cycle a.c. circuit. The voltage first stepped through suitable iron core transformer and the high voltage cur- rent rectified through conventional vacuum tube since the condenser can charged only with direct current. resistance inserted the line limit the rate charging the con- denser bank few amperes, taking paratus, conventional spot welding timer control employed cut off the primary current after the condensers are fully charged. The capacity 800 microfarads. weld two round bars dissimilar metals, in. diameter, the condenser charged 4300 volts. Discharge the condenser takes place automatically when the work trigger released. General-Purpose Rod Welder \Vith reference the general-pur- pose bar type welder, the two pieces are solidly clamped suitable dies, one being stationary and the other being held back against spring air pres- sure, with the surfaces welded about in. apart. After the trigger released, the movable die shoots for- ward and when the ends the work pieces are about 1/16 in. apart, 4000 volts the air breaks down and arc established across the gap. dicated previously, the current wave about 5000 cycles per YPICAL applications the Vanco percussive welding process the joining dissimilar met- als. Left: Stellite tip bronze valve stem; middle, Stellite tip stainless steel valve stem, and right, silver graphite contact disk copper rod stem. it q ¥ . 3 and with peak the first cycle about 70,000 amp., rapidly decaying zero, however. fact, the mass the moving system and the driving pressure adjusted that the end about 0.0005 sec. after the break down, the parts are brought into me- chanical contact. Several cycles the arc will have taken place this time, however, and the metallic surfaces will have been heated high just before contact. The impact pro duces the weld before any co