The Iron Age 1940-06-13: Vol 45 Iss 24

JUNE 13, 1940 VOL. 145 NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor News Editor Technical Editor Machinery Editor Art Editor Editor Emeritus Associate Editors Washington Editors MOFFETT JAMES ELLIS Resident District Editors CAMPBELL ROBERT BINGHAM Pittsburgh Chicago Cleveland Detroit Editorial Correspondents Buffalo Cincinnati FRAZAR CHARLES POST Boston San Francisco CLYDE ENNIS Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis LEROY ALLISON Newark, N. J. HUGH SHARP Milwaukee 4 Editorial Technical Articles Aluminum Alloy Practice Copperweld Goes Alloy Deep Drawing Test for Sheet Metal Bethlehem Installs New Pipe Mill..................... Design and Welding Fabricated Machinery What's New Welding Feature Reports News and Market Reports News Machine Tool Activity 100 May Steel Production........ Non-Ferrous Metal Market.... Personals and Obituaries..... Scrap Market and 102 Metal Working Activity Construction 104 Comparison Prices ....... and Steel Prices......... 106 Summary the Ferroalloys, Pig Iron Prices... The Industrial Pace.......... Warehouse Prices District Market Reports....... Sales DIX, Manager Reader Service Owned and Published CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and Séth Offices Philadelphia, Pa., 239 West 39th St., Advertising Staff Emerson Findley 0,5 Id levelan Hottenstein, Otis Bldg., Chicago U.S.A. Leonard, 239 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 239 39th New York W. J. Fitzgerald j 428 Park Bldg., Pittsburgh Don Harner, 1595 Pacific Avenue, Long Beach, Cal. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-Prusident GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Subscription JOHN BLAIR MOFFETT, Secretary United States and Possessions, Mexico, Cuba, $6.00: Canada, Foreign, $12.00 year. JULIAN CHASE, THOMAS Single copy, cents. Annual Number $1.00. BUZBY, FAHRENDORF, Cable Address, HARRY DUFFY CHARLES HEALE . Copyright, 1940, Chilton Company slight push the foot bar, easy pull the hand rail, and the new welder ready away its heavy-duty 10'' wheels. The built-in Westinghouse breaker permits shutting down the ma- chine and protects against sustained overloads. ADJUSTMERT —in — ne— — Current adjustable steps from 250 amperes. Steps are clearly indicated. Plug and you’re ready weld. Price includes complete equipment; welding helmet with lens, welding leads, scratchbrush, electrode holder, generous length primary cable and lbs. assorted electrodes. 22—THE IRON AGE, June 13, LETE WITH ALL See the New All-Purpose FlexArc display your nearest Westinghouse Welding Dealer. With complete line Westinghouse FlexArc Welders and Westinghouse FlexArc electrodes for both a-c and d-c can supply the equipment best suited your requirements. For information write Dept. 7-N, Westinghouse Electric Mfg. Co., East Pittsburgh, Pa. — JUNE 13, 1940 ESTABLISHED 1855 Machine Tools Munitions RECENT article the Saiurday Evening Post characterized the Amer- ican machine tool industry and “bottleneck.” Both these allegations are wrong and misleading, was the indirect reference the opinions and statements the undersigned. industrial war baby one that born war, nursed war and killed when war ceases. There have been and always will such short-lived industries fathered war. The American machine tool industry, industry, has been existence for little less than century. Before that one could hardly industry. During that time has been called upon supply its products for war just three times, not counting the Spanish-American inci- dent. Three times hundred years could not called forming During war there demand for shoes and blankets and canned salmon and thousands products every kind needed quantities armies, but that does not make these industries war babies. They are just peace babies temporarily recruited serve military needs. And so, too, the machine tool industry. The machine tool industry, even what call normal times, faces widely fluctuating demand from year year. fortunate through 10-year period with three four profitable years six seven unprofitable ones. not know any fortunes built machine tool making that are all comparable with those built upon many other in- dustries. With some few exceptions, the ownership and management the industry are vested working proprietors who have come through the ranks from bench drafting board. true that the industry has been receipt large foreign orders for the past several years. But these were not taken the expense American customers. The foreign orders are these shops because American customers, through fear the New Deal and its works, post- poned investment and replacement and permitted obsolescence creep up. Even that, the tool builders have seen that hastily awakened American demand has not suffered deliveries. One American company engaged important armament work, for example, the first February had placed order 817 machine tools. many these, final instructions and complete information had not been given the time the builders. Yet, the end April, 820 machine tools had been shipped this company, including some later orders. performance! There will bottleneck machine tools Bill Knudsen left specify priorities the machine tool committee appointed last week. 4 | g | j i 2 > Extra profit comes from more pay load, and more pay load gained reducing dead weight. Inland Hi-Steel, with twice the yield strength ordinary carbon steel, makes possible the cutting structural weight 50%. Inland Hi-Steel fabricates easily, bon steel part equal strength. Write today for Inland Hi-Steel Bulletin No. 10. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS Dearborn Street, Chicago Sales Offices: Milwaukee, Detroit, St. Paul, Kansas City, Cincinnati HIS article describes the aluminum casting alloys used Britain and the Con- tinent, the types additive elements, and the uses which such alloys are put. In- cluded very informative list some alloys, their composition and some their general physical char- acteristics. ARTIME demands tor and naval construction led record consumption fig- ures for aluminum Europe, practi- cally the entire production being ab- sorbed for these purposes. The bulk the metal converted into alloys for casting working, and study these rendered difficult reason the designations given the various alloys. Not only these alloys vary different European countries but dif- ferent names are used various pro- ducers for identically the same metal, that given alloy will sometimes have many six names. the same time one title will not infrequent- alloys different composition, prop- erties and treatment. assist survey, list has been appended this article which these various titles are shown together with their composition and some note the origin and uses the metal. While most these alloys have some com- mercial status the present time few have been included which have gone out use, although the names have ERNEST PANNELL British Aluminum Co., Ltd., Bristol, England ° and not unusual obsolete mixture French metallurgist, Douche- mont, short time back, introduced system classification which all aluminum alloys were included six groups according whether the main addition the metal was (1) silicon, (2) magnesium, (3) magnesium sili- cide, (4) (6) manganese. The effect and the action these additions are very different, and thought better detail the added metals three groups fol- lows: (A) all light alloys for foundry per cent pure aluminum which, while seldom cast pure form the basic material. (B) COPPER, MAGNESIUM, SILICON, ZINC, ETC.—These are added proportions from per cent. Without going into metallurgical theory can said that amounts they strengthen the individual crystals solid solution otherwise, the same time reducing melting point and improving casting qualities and thus producing simple normal alloy. Class additions may also the form, copper-nick- copper, zine, el, silicon-copper, etc. (C) COPPER, MAGNESIUM, LITHIUM, elements are added normal alloy above with view heat treatment. These elements small proportions form ° ° compounds such copper-aluminide, which capable being dissolved when heated are and precipitated extremely small particles after quenching. Dispersed this finely divided form throughout the metal they form which further strengthen the crystals and prevent their being torn apart under stress. This effects marked improve- ment hardness, tensile strength elon- gation, machinability, and other prop- erties. Heat treatment has been the subject intense study for the past years and full information the treatable elements not complete. Nearly all alloys this class, however, depend metals such lithium appear have been introduced into use because mag- nesium was for period covered patent. Class additions, will noted, can added either pure alu- the latter general for foundry work. (D) MANGANESE, TITANIUM, NICKEL, IRON, CERIUM, CADMI- UM, SILICON, centages these elements are often added normal treated alloy with view other improvements. For example, casting finer grain with somewhat reduced shrinkage fol- lows the addition manganese titanium, and the latter appears ac- celerate the action heat treatment. Nickel manganese will increase the THE IRON AGE, June 13, ' y 7 » | 4 ty Al £ ! 4 3 rey res ar a4 hot tensile strength the casting. An- timony silicon used improve corrosion resistance, while tin and antimony give improved machining properties. Furthermore, action between some these additions and the heat treating elements will oc- casionally modify the properties the alloy. Class components are some- times added metals the normal class which are not treated. The foregoing statements are sum- marized the table below which will helpful the study European aluminum alloys. CASTING ALLOY GROUPS Improved Pure Alloy Alloy Alloy Aluminum Copper Copper Manganese Copper- Titanium Tin Copper- Antimony Nickel Etc. Any complex alloy can studied the above basis. must borne mind that while aluminum-copper composition straight al- loy can heat treated, which case small percentage the copper forming the compound can precipitated thus forming alloy although the composition un- altered. Furthermore, all commercial aluminum contains from 0.3 per cent upwards both iron and silicon. magnesium alloy Class there- fore, small proportion the mag- nesium will combine with this silicon, heat treated, converting Class B-C alloy. Since most European foundries are working Government specifications and inspection, rigid control forced quality and foundry condi- tions. Practice has developed the point that quite small foundries are now dealing with heat treated and There has general leveling-up tech- nique, especially England, and the status casting production tained scientific basis during the last years. While many the propri- etary and their treatment are subject patent, they are quite gen- mutually agreeable terms—there thus monopoly and the widest use made new developments and in- ventions. The following table sets out alphabetical form the aluminum cast- ing alloys, which most are now commercial use. has been endeav- ored show duplications where they exist, and also indicate the sources and uses the various metals. The composition shown generally av- erage figure since analysis varies be- tween maximum and minimum limits. Aluminum assumed contain nor- mal amounts silicon and iron; where these elements are shown they have been added the normal amount. Physical properties are not quoted be- cause the great variation testing methods. Generally tensile strength from 25,000 40,000 Ib. per sq. in., elongation from per cent, and Brinell hardness from 130. already indicated, patents exist most countries covering many the treated and improved alloys. While has not been general cus- tom this country designate alumi- num alloys name, few American compositions have been included for comparison purposes. European Aluminum Casting Alloys Magne- Cadmium complex alloys. sium Cerium Silicon Chromium Silicon- Copper Silicon Silicon- Etc. Nickel Zinc Copper ACIERAL AERON Aluminum 94,7 Aluminum 95.9 4.0 1.5 Heat treated castings Developed cast duralumin the Baush Machine Tool Co., Spring- field, Mass., patents Lavandeyra. AERAL Aluminum ........ 90.5 Magnesium 1.2 0.2 Cadmium Silicon 2.5 Heat treated, used for cylinder blocks and heads Wm. Mills, Birming- ham, England. AEROLITE Aluminum 85.0 14.0 Manganese 1.0 Piston alloy high hot tensile strength. Alternative compositions are also reported. ALNEON Aluminum 88.0 10.0 Copper normal alloy cast sand blended with metal particles give chilling effect, according the process Strasser, Munich. ALPAX Aluminum 87.0 Silicon 13.0 modified with sodium for grain refinement. Devel- oped Dr. Pacz, Cleve- land, Ohio, and other investigators. 26—THE IRON AGE, June 13, 1940 ALPAX GAMMA 87.3 Silicon 0.3 0.4 improved form giv- ing much higher yield point and higher tensile strength and hardness when heat treated. ALUFONT Aluminum Silicon Magnesium 0.2 0.6 Titanium 0.15 series improved and heat-treated casting alloys for sand and per- manent molds developed Dr. von Zeerleder the Neuhausen, Switzerland. Alufont improved ALUFONT Aluminum 84.4 12.0 2.0 0.2 Developed above. Similar Lynite 145 used 1921. ALUFONT Aluminum 83.5 Zinc 2.0 2.0 0.5 Developed above and said heat treat- but with outstand- ing results. ALUMAG 95.5 4.5 form magnalium used the Trefileries Laminoirs Havre, France. ALUMAC Aluminum 87.0 Silicon 13.0 Alpax alloy used for die casting. ALUMINITE Aluminum 84.0 23.0 3.0 Developed Bruff, New York, but little commercial applica- tion. ALUSIL Aluminum Piston alloy the hyper-eutectic class de- signed for low thermal ex- pansion. ALUVAC Aluminum ........ 87.0 Silicon Alpax used for die castings the Fonderies Precision, Nanterre, France. ANTOX Aluminum series alloys hav- ing commercial cation. Aluminum Copper Titanium Pacz. Titanium promotes grain refining and accel- erates heat treatment. ARGILIT 90.0 Silicon 2.0 present commercial applications are known. BAUSH 6.5 0.5 Developed the Baush Machine Tool Co., Spring- Mass., for heat treated castings. Pouring aluminum aircraft parts plaster molds. BIRMABRIGHT Brass Corp., Detroit. Heat lron 1.2 95.0 treated and widely used Cerium 0.2 Manganese 0.5 cylinder heads and hig Extensively used Brit- Alumi 80.4 temperature parts en- ain especially for corro- sion resistance. Developed CINDAL the Birmingham Alu- extensive group minum Casting Co., Eng- alloys developed land. Tullis, Cindal Metals BIRMALITE England. All are Aluminum 89.2 treated when molten with Magnesium 0.3 similar compound pro- 0.5 duce sound castings for Similar CERALUMIN corrosion resistance. Used the Birmingham Aluminum Casting CRANAL England, for pistons. Nickel Aluminum 87.0 Silicon 1.6 Silicon 13.0 BIRMASIL Magnesium 0.1 Alpax used the Aluminum 85.5 lron 0.8 Fonderies Forges Silicon 11.5 Cerium 0.2 Crans, Cran Gevrier, Nickel 3.0 France, production low expansion alloy with high hot tensile prop- erties developed the above. BOHNALITE Aluminum 88.5 Copper 10.0 1.2 Magnesium 0.3 Piston alloy produced the Bohn Aluminum alloys patented Stone Co., Deptford, England. Heat treated and used for intricate castings. CERALUMIN Aluminum 92.7 Copper 2.5 Nickel 1.5 Silicon 1.2 Magnesium 0.7 very large automotive castings sand molds. DURANALIUM Aluminum 93.6 6.0 heat treated casting alloy produced the Du- rener Metallwerke, Ger- many, for use conjunc- tion with Duralumin. THE IRON AGE, June 13, | yas | pe DURALINOX 94.6 Similar the above but produced the Societe Duralumin, Paris. EUTECTAL Aluminum 95.5 1.5 Silicon 1.0 0.8 heat treated casting alloy developed France. FULLER ALLOY Aluminum heat treated casting alloy free from copper and good corrosion re- sistance. Developed the laboratories the eral Electric Co. GAMA Aluminum Nickel 1.5 Magnesium heat treated casting alloy developed France and intended for high tem- perature engine parts. HIDUMINIUM series heat treated alloys developed Rolls Royce and listed under the designation RR. HURON Similar Baush Metal. HYDRONALIUM Aluminum Magnesium Silicon 1.0 One large group alloys developed Ger- many and having from per cent magne- sium. Not heat treated. HYPERSILICON Aluminum 76.0 Silicon 2.0 low expansion piston alloy. 28—THE IRON AGE, June 1940 K.S. 245 Aluminum 78.5 14.0 0.7 Manganese Nickel heat treated piston alloy developed Karl Schmidt, Germany. K.S 280 Aluminum Silicon Magnesium Nickel 1.2 Similar the above but designed for minimum thermal expansion. LAUTAL Aluminum 94.0 4.0 normal alloy for both casting and work- ing developed the Vereinigte Aluminium Werke, Lauta, Germany. LOEX Aluminum Silicon 14.0 Nickel 2.0 Heat treated piston al- loy designed for low ther- mal expansion and ease machining. Developed America. LYNITE 145 Aluminum Zinc 2.5 One group cast- ing alloys designed achieve high strength the use iron. Now only limited commercial use. Aluminum 84.0 Copper Adam Detroit but little used American prac- tice. MAGNALITE Aluminum 94.7 1.3 1.5 Used for pistons Levett New York be- fore the development and "RR" alloys. MAGNALIUM Aluminum 95.0 5.0 Used for foundry work the Westinghouse Electric Mfg. Co. and others 1920 but later discontinued. MIRALITE Aluminum 87.0 12.0 Tin British piston alloy longer commercial use. Aluminum 89.0 ........... form Alpax devel- the Metropolitan Vickers Co. Trafford Park, England. NEONALIUM Aluminum 90.0 10.0 normal alloy molded with metal blended sand secure greater chilling effect when cast. Devel- oped Strasser Mu- nich, NOVALITE 85.0 12.5 1.4 0.8 piston alloy formerly used commercially Ger- many. NURAL Aluminum lron One group cast- ing alloys Germany but with orig- inal features. PACK ALLOY Aluminum ........ 90.5 Copper 4.0 4.0 1.5 Developed the Doehler Die Casting Co. for die castings. PANSERI ALLOY Aluminum ........ 82.6 11.5 Nickel Copper 1.0 0.4 Piston alloy developed PANTAL Aluminum 93.8 5.0 Magnesium ...... 0.6 0.6 Used Germany for heat treated sand and permanent mold castings. QUARZAL Aluminum 94.0 lron European alloy stated used for bearings. QUARZAL Aluminum 78.0 15.0 6.0 Piston alloy the same class the above. 88.9 3.0 Copper 0.5 Titanium Developed Sutton and others the Royal Aircraft Factory for hot tensile strength. Magnesium lron Silicon Nickel Titanium One the Hiduminium alloys developed Hall | and Bradbury the Rolls Royce Co., Derby, and promoted High Duty Alloys, Slough, England. Used for sand castings and heat treated. Aluminum 92. Copper Magnesium lron Silicon Nickel Titanium above but used for permanent tion. SEEWASSER Aluminum 95.0 Magnesium 2.3 Manganese 2.5 Antimony 0.2 Developed Schmidt Neckarsulm Germany, for resistance marine corrosion. SILUMIN Aluminum 87.0 Silicon 13.0 Similar Ger- man designation. STALANIUM Aluminum 92.0 Magnesium 7.0 Antimony 0.5 Similar designed for good resis tance corrosion. STAY ALLOY Aluminum 88.9 Copper 11.0 Titanium the Alumnium Castings Co., Cleveland, for per- manent mold castings with SYLCUM Aluminum 81.8 Silicon 9.0 Copper 7.3 Nickel 1.4 Manganese 0.5 alloy devel- oped Germany for hardness and low sion. THALASSAL Aluminum 95.0 Magnesium 2.3 Manganese Antimony 0.2 ser; used French prac- tice. Chromium Magnesium 0.5 Heat treated alloy de- signed for corrosion resis- tance. WILMIL Aluminum 87.0 Silicon Similar Alpax. veloped William Mills Foundry Co., Birmingham, England. ALLOY 92.5 Developed England survey the foregoing list alloys shows that could reduced less than half duplications were eliminated. Small anal- ysis are indicative the individualis- tic attitude producers and but these are gradually being leveled out the standardization for under Government control. regards nomenclature, must admitted that distinetive names give better picture ditferent metals and are the same time more easily memorized than num- bers. The many compositions foun- dry alloys use amounts magnesium, manganese, grain. TITANAL for heat treated motor Aluminum 81.9 pistons and cylinders hav- Copper 12.3 ing high hot strength. Now SUPRA Silicon 4.3 partly superseded lron 0.7 alloys. Aluminum 73.0 Magnesium 0.8 piston alloy devel- Manganese 1.8 heat treated. 0.7 Silicon 2.5 hypereutectic alloy VERILITE foundry alloy for gen- for low expansion pistons. Aluminum 95.5 eral work produced the Claimed have self- Copper 1.0 Birmingham Aluminum hardening properties. Nickel 1.5 Casting Co., England. chromium and similar elements are ex- plained the fact that much the metal coming into the foundries scrap from aircraft sheet metal shops. These elements are kept under analyt- ical control, however, and afford sim- ple means producing castings for heat treatment. Cast RECENT paper before the British Cast Iron Research Association. gives survey the microstructures, tendency chill, mechanical proper- ties (such Brinell hardness, machin- ability, strength, deflection and repeated pact values) and air and oil hardening capacities cast irons having chromi- contents between and per cent and silicon contents between and per cent. may summarized follows: (1) per cent per cent ferrochromi- added crucible melts increased the chromium content the resulting cast average 0.6 per cent; the chromium content stabilized the pearlite and secondary cementite and caused white-iron eu- tectic replace graphite, but did not cause self the replace- ment pearlite martensite; (3) cast irons normal total-carbon con- tent, the chill producing action per cent chromium neutralized the chill reducing action about cent silicon; (4) creased the Brinell hardness and re- duced the machinability. most com- positions increased the mechanical strength and reduced the deflection; (5) the chromium creased, the eutectic as- sumed the form carbide crystals ferrite matrix, instead austenite globules carbide matrix; (6) ex- periments not included this paper showed that chromium raised the freezing point the white-iron eutec- tic. THE IRON AGE, June 13, 1940—29 4 Pore RE > ‘ “ef. ty | q | ITH electric furnace alloy consumption Copperweld Steel Co., Warren, Ohio, joins the parade alloy steel makers with experienced personnel, modern electric furnace melt shop equipment and practice, completely re- constructed rolling mills and plenty wide open space for future expansion. Present capacity for grades alloy steels the Warren plant approximates 12,000 tons in- gots month, while the rolling mill equipment capable finishing about 20,000 tons alloy steel products month. The Warren plant will furnish the Glassport, Pa., plant the steel used the manufacture Copperweld (copper covered wire and rods), but Glassport requirements will not exceed per cent the Warren plant ca- pacity. Frederick Griffiths, whose history well that other execu- tives appears elsewhere this story, was given free hand building the new steel plant degree that would put position make, serve and research the best alloy steel production. expected that when full time production obtained Copperweld will employ approximately 600 employees. line with present day trends, the company has built centrally located metallurgical and chemical laboratory, housing the latest equipment available for the testing steel. There also etch house near the billet storage building for macroetching billets and bars. 30—THE IRON AGE, June 13, 1940 Copperweld Goes Copperweld grades SAE alloy steels automo- tive and electric furnace quality in- sisting steel, aircraft quality steel, tool and special steels and stainless steel. Each the two 25-ton Swindell- Dressler electric furnaces are serviced 12,000 k.v.a. Westinghouse trans- former which has range sec- ondary voltages permitting full flexi- bility from the rapid melting light scrap the holding and refining volt- ages. Each these electric furnaces will make average heats net tons. 6-ton Heroult electric furnace com- pletes the present melt shop setup. desirable safety feature the 25-ton furnaces obtained having the flexible cables water cooled and in- sulated from one another rubber hose containers. This setup reflects compactness and new feature rub- ber ball flexibility used. The furnaces are claimed the largest using top charging, and the combination swinging roof witha rack MELT SHOP furnace, STOCK HOUSE Transfer car: furnace Layout the new Copperweld melt shop four point suspension considered unique this design. This latter feature has reduced eliminated the heavy stress roof refractories, and the four point suspension the roof makes changing simple and rap- progress, especially since all roofs are interchangeable. Operation the lift and swinging root carried out smoothly the use heavy oil hydraulic lifting ram into which incorporated trans- verse oil hydraulic cylinder for swing- ing both directions. These rams are interlocked and one lever operates the whole system. The oil system low pressure type and each inter- connected. Working bottoms the furnaces are lined with Ramix, prepared mag- nesite refractory made Basic Do- lomite, Inc., Cleveland. This when mixed with water and rammed into place, air-sets dense, mono- lithic mass. Possible damage the electric furnace roof through burning- the bottom lining high tempera- conveyor Alloy... ture, thus avoided. Under furnace operating temperatures, the material develops high resistance slag and metal penetration, chemical attack and erosion, Advantages claimed for the material include reduced maintenance, longer hearth life, and faster production due the reduced conductivity Ramix. The charging the furnace ac- complished two drop bottom buckets and the time element short because the raising and the swinging the roof takes only sec. each direc- tion. The scrap drop buckets have sectional bottoms kept place rope which burns when the bucket po- sition the top the furnace thus releasing the scrap. The “balance” the electric fur- nace setup accurate that im- mediate response from the regulator the electric arc both directions permitted. This, more than any other feature, assures accuracy tempera- ture and the proper reactions between the slag and steel bath. The electrode CAMPBELL Pittsburgh Editor, The Age travel almost twice much previous practice which, claimed, reduces one-half shut-downs for electrode slipping. The high electrical input these two electric furnaces brings about the “melting the whole charge within one hour. Refining then car- ried out under the available flexible inputs and “under the pouring utilized metallurgical cleanliness. The entire melt shop layout com- pact, and the entire technique from scrap storage and handling ingot stripping accomplished with min- imum time and operations. Two ingots, each weighing 2100 are poured simultaneously from double-nozzle ladle. feature the melt shop equipment newly de- signed ingot stripping machine built Morgan Engineering Co., Alliance, Ohio. The equipment consists two ingot mold tilting machines, one 100- ton stripper and ingot mold car. The ingot mold tilting machines and stripper operated through motor driven oil hydraulic unit and the ingot mold car operated track chain drive and electric motor. Controlled one operator from the operating pulpit, the cycle opera- tion follows: After molds have been poured, they are transferred from the pouring three time, overhead crane with multiple hook bale, and deposited vertical position the first ingot mold tilting machine. The tilting machine pro- vided with automatic clamping de- vice which locks the molds the tilt- ing The ingot tilting machine then deposits the three loaded molds horizontal position the ingot car. The ingot car conveys the molds the stationary stripper. The molds automatically engage with the stripper head and are stripped, one time, the stripper plunger. The stripper has two cylinders designed provide rapid push out and return motions after ingots have been loosened from molds. the ingots are being stripped, the first ingot tilting machine re- turned upright position and re- ceives the second group loaded molds crane from the pouring plat- form. \iter stripping, the ingot car fur- ther conveys the empty molds the second ingot tilting machine. The molds automatically engage the clamp- ing device and the tilting machine re- turns the empty molds the original New ELECTRIC FURNACES—Two 25-ton removable top fur- naces (charge net tons), each with 12,000 k.v.a. trans- former. One 6-ton Heroult furnace. otal capacity for melt shop 12,000 tons ingots month. STOCK HOUSE--Last word scrap segregation swift handling. Scrap buckets discharge scrap when rope bottom burn POURING arrangement pouring from each ladle. Each ingot measures weighs 2100 lbs. INGOT MOLD STRIPPER—Totally new design ingot mold stripping (see article for details) three molds brought stripper one time. BLOOMING MILL HEATING FURNACES—Three door furnaces, newly designed, having ten burners wall and built the incandescent gases envelope ingots. (See article for details.) BILLET HEATING FURNACE—One continuous pusher type having two firing zones, preheat and soaking. Gases can exhausted independently from either firing zone. Plant Glance BLOOMING MILL—One three mer, 1500 hp., 2300 volts, a.c. motor. 24-in. BAR MILL—With both saw equip- ment. Has pit capacity for slow olin illets 1200 hp., 2300 volt a.c. Products from thi cooling bed thence billet storag ilding cleaning equipment BAR MILL—Two 3-high and hot saw equipment mill has additional slow cooling pits 12-in. and 9-in. BAR MILLS—Five stands 12-in. and two stands 9-in. with double cooling bed 210 ft. long and two rod reels. LABORATORY—Completely equipped make every re- quired test and inspection alloy steels. PRODUCTS PRODUCED—Billets and bars from one-half inch eight inches rolling and larger irregular sec- tions are pressed. THE IRON AGE, June 13, & x = cooling pits, pickling tanks and are lar = located. with large cooling bed 1ae ear es | LEFT View melt shop from form toward fur- naces. BELOW Alloy heat being poured, using two nozzles. upright The three empty molds are returned the pouring plat- form crane, completing the cycle operation. After leaving the stripper the alloy ingots, unless stored the melt shop ground the blooming mill heating furnaces. Heating the ingots ac- complished three double chamber, side door furnaces, new design. Pittsburgh, designing these furnaces adopted new method firing rear wall which throw flame under the arch towards the door. are arranged draw the incan- descent gases front the doors and back through the rows ingots. unusually uniform heating results and the furnaces are controlled for atmos- phere, temperature and pressure. LEFT New type stripper for alloy steel ingots. stalled continuous pusher type nace the company’s bar mill. This furnace has two zones firing, preheat and soaking, with means, dently from either firing zone. This arrangement makes possible use only one firing zone the charge small and this case either the pre- heat soaking zone can used for full and proper heating the bars. Rolling mill equipment Copper- weld includes blooming mill, bar mill, bar mill, bar mill and bar mill, details which are shown elsewhere this article. United Engineering pass design. The entire designing and engineer- ing the Copperweld plant was under gineering Co., Cleveland, construction work was carried through record time Uhl Construction Co. The working floor area under roof, modern daylight buildings, and com- pletely served cranes, over 320,- OOO sq. equivalent aproximately acres. % HREE major objectives were uppermost undertaking the redesign press used cut blanks into rotor and stator lamina- tions for a.c. motors the plant the Reliance Electric Engineering Co., Cleveland. The operation what known “separating,” parting with die, rotor and stator lami- nation from each blank into the press. The first consideration was vide greater protection for the opera- tor who the original setup insert and remove the blanks hand from beneath the dies. The second consideration was develop auto- matic means segregating and stack ing the rotor and stator sections each blank these emerged from the separating operations. The third con- sideration was increase the output the press sufficiently make feas- smoothly moving production line. The blanks come the separating press from other stamping operations which have provided (1) the proper sized shaft hole, (2) the correct out- side diameter for the finished stator, and (3) succession notched open- ings around the periphery the blank which will serve the coil slots the stator lamination. The separating op- erations performed the revamped follows this notching the stator coil slots, and precedes the as- press sembly the stator laminations into finished stator frames. the original operation the sep- arating press the blank was placed hand over plug the center the die, and the press clutch tripped. the press had operated, the stator sec tion dropped out the back the press and into pan; but the rotor section had pried off the plug the die—again hand. Both types laminations then picked hand, separated in- two stacks and lined index keyways and the proper side with relation the press burrs which had been raised. This opera- tion, again, was necessarily slow one and offered considerable hazard the fingers and hands. the Press Operation Revamped the presence the operator’s hands beneath the press dies, the construc- tion the dies was revised that blanks are now fed into through chute, and are mechanical- positioned beneath the dies the use stops. Knockout rings and pins were introduced automatically strip the rotor sections from the die follow- ing the separating operation. The rotor lamination drops out the die and down the discharge chute under the corresponding stator lamina- tion. hole, cut the discharge chute the back the press, allows the rotor lamination piece) drop through into separate, lower chute. The stator lamination (of larger diameter) slides down the upper discharge chute. The stator laminations are picked moving rubber conveyor belt and carried stacking unit shown accompanying illustration. Stacks lined-up stator laminations can from the stopping either the press the stack- and are weighed scale into piles the correct size produce finished stators. removed The rotor laminations they slide down the lower discharge chute are tilted edge, rolled sideways and picked another rubber belt con- veyor which carries them and onto spindles which they stacked until removed notched required the specifications mo- tors going into production the time. complete press, conveyors, and ° PERATOR feeds blanks into chute (above) which auto- matically them (Right) Stator lami- nations come off con- veyor foreground. They can removed from stacker without interrupting the press. stacking unit are used blanks in. diameter. For larger size blanks in. diam- eter, the rotor sections are handled previously described, but laminations, being too big pass back through the press, are taken out the dies the front and are shoved down special chute provided along. the out- side the press. This chute carries them the stacker unit previously de- scribed. Because the large size these laminations removing them hand does not represent the hazard in- volved with the smaller sizes, but naturally slower. The output this press has been doubled result the foregoing innovation. TRETCHER Strains: regard the development stretcher strains certain points inter- est were revealed examina- tion series partial pressings produced the slower rate draw- ing. During the very early stages drawing stretcher strains appear intersecting spiral formation the flat rim the blank. ‘As the drawing proceeds and the strains become great- these particular stretcher strains disappear, while another system, based transverse axes the strip, appears the flat base the cup. later stage this system disappears turn, leaving clean surface. mentioned above, this latter formation stretch- strains not independent the rate drawing. The stretcher strains are characteristic, course, the state actual vield the mild steel and therefore strains not exceeding about per cent. Strains this order occur the rim very early stage, and soon they become greater the stretcher strains begin disappear. Strains the base the cup arise the tension the cylindrical por- tion the cup draws metal round the radius the head the punch, and are probably more those the rim, depending the punch radius, conditions lubrica- tion, and also evidently, the speed drawing. the blank diameter increased with any particular punch radius the 34—THE IRON AGE, June 13, 1940 stretcher strain figures found the base the cup show greater ment certain point, but tend disappear still greater diameters. This indicates that, with small blanks, the base the cup only just reaches the yield point; with larger blanks the strain corresponds the full yield; and with still larger ones the strain has passed beyond the yield into the stable plastic range. Inspection cups produced from given blank diameter means punches various radii shows that the stretcher strains are more fully developed, the case the larger have more completely disap- peared, when the punch radius large. This observation confirms that the strains are more readily transmitted over gradual curvature the punch. These observations suggest that may sometimes possible avoid stretcher strains practice allow- ing the affected part greater freedom strain that has completely passed through the critical stage the end the pressing operation. note that obvious stretcher strains were detected any stage the radiused portions al- though the material these regions must necessarily pass through the crit- ical range strain. The reason underlying explains the efficacy roller leveling preliminary stage commercial drawing operations. the process bending the various layers the strip sheet pass through the point different stages, and the stretcher strains develop locally, and much finer form than when the whole thick- ness the material passed through the yield point the same time. Care- ful inspection roller leveled sheet reveals minute and, therefore, quite unobjectionable stretcher strains, and material bent the experimental sub-press these merely produce slight sand-blasted appearance the surface. analogous effect found when passing through stage torsion test. Lubrication order examine the effect lubrication, was decided employ, for exploratory purposes, single diameter blank (4.0 in.) and single speed drawing in. per min.), and compare results the basis autographic diagrams and maximum punch loads. series preliminary tests us- ing mild steel blanks, was found that the lowest punch loads among eight representative lubricants tested were given those containing graphite, either the dry form finely divided suspension water. endeavor explain and ascer- tain the range efficacy graphite, tests were made mild steel blanks larger diameter and various speeds. was found that blanks in. speeds with maximum slightly under 13,000 14,800 4.4 in. diameter failed draw any speed. Graphite improves the drawing properties mild steel markedly slow rates drawing, and slightly the higher rates approximating commercial | | N 4 | | | practice. the same time, the speed grease lubrication, graphite. The reason for this prob- ably quite simple one. The film grease between the blank and die tends expelled under the high inter- facial pressure and the drawing ac- tion, while the graphite, being more solid nature, resists expulsion and rather pressed into the surface the blank. the mechanism ex- pulsion the grease film there time effect; the slower the drawing process the more complete the expul- sion will be. Hence the grease film less impaired high speeds and more efficient lubrication provided. This time effect does not exist with the graphite, which maintains film under all conditions speed. The fact that another solid lubricant chalk was unsatisfactory due, doubt, not its expulsion, but its poorer intrinsic lubricating properties. The essential function lubrica- tion the underside the blank reduce the friction over the radius the die ring (Fig. 3), that the radial tension necessary produce the radial drawing the blank not augmented unduly transferred round the radius the die into pure tension the cylindrical portion the cup Hence, lubrication the radius reduces the tension the portion the pressing most liable break, and also the load for the punch. Hence, either larger blanks can pressed lower punch loads are The effect lubrication between the blank and blank-holder the re- gion and reduce the radial tension some extent; but since, has been shown, the punch load not appreciably increased the consider- able ironing due blank data dependable testing procedure for determining deep drawing qualities metals are extremely timely. Therefore, this informative treatment the problem Professor Swift has brought forth enthusiastic response England. the first part this article last week, the author discussed cupping tests and the drawing test, and described the autographic sub-press devised for the deep drawing tests. Herein, conclusion, data are presented stretcher strains, and considerable ex- perimental work the important subject lubrication correlated. clearance and since the lubricating film most likely persist near the trailing outer edge the blank. the conditions this region are not likely very important. The other region which the con dition the upper surface impor- tant that where radial pres- sure may exerted the punch forming the curvature over the radius the die, and where additional pressure induced if, and when, iron- ing commences Since the tending draw out during the whole pressing operation, there will small but positive slip between the sur- faces the cup and punch, and any pressure between the two will intro- duce friction which, already ex- plained, will tend concentrate the region This friction will not affect the radial tension causing the radial drawing the flange between and but will supply some the force necessary provide this tension, and will therefore relieve the cylindrical portion the cup this extent. the pressure and adhesion were sufficient, there would need for any tension all the cup and the whole the punch load would transmitted the blank where its thickness greater than and therefore more able sustain the load. The actual value the punch load, however, would not affected distributed between the two. This picture the mechanism lubrication the drawing process ex- plains the experimentally established when the bottom lubri- cated definite way the drawing load independent the condition the upper surface; when the bottom unlubricated, the drawing load greater, but, again, independent the condition the upper surface; with good lubricant the upper surface, the cup will break punch load which capable sustaining with inferior lubricant, with lubri- cant all. the practical standpoint, these observations suggest that advan- tageous insure lubrication the lip over which drawing takes place, but the same time avoid lubrication between the punch and From the standpoint testing and fundamental research, however, probably better lubricate both sides, and possible allow adequate clear- ance between the punch and die insure that all the punch load transmitted through portion the cup. the purpose mor comparison the efficacy THE IRON AGE, June 13, 1940—35 DSc. | ) | Pus | forms tests lubrication, were made with mild steel, brass, and various aluminum blanks. The mild steel and brass blanks were 4.0 in. diameter, and the aluminum blanks 3.5 in. diameter. common speed drawing 1.5 in. per minute was adopted, the radii punch and die were each 0.25 in., the blank clearance was 2-3 .mils., the radial clearance mils., and the lubri- cant under test was applied both short, the con- ditions were made comparable every sides the blank. possible way. The tests mild steel blanks were made first, and upwards fifty lubri- cants were used. order save unnecessary labor, some the lubri- cants which unsatisfactory essen- tial function friction over the ra- dius the die rin with mild steel were omitted from the tests with brass and aluminum blanks, but all which promised interesting useful results were included. The range punch loads varied the mild steel series from 11,300 15,700 the brass series from 9300 Ib. 12,100 and the alu- minum series from 1930 3230 Ib. Certain the lubricants caused failure draw with mild steel and aluminum, but the blank diameter was well within the capacity the brass strip, and actual failures were re- corded. The best results and other represen- tative results from the three sets blanks are shown Tables comparison thesé tables shows TABLE Lubrication Mild Steel Blanks Maximum Lubricant punch Remarks load, 12,100 Anhydrous, mixed min. oil 12,800 Oil, soap, water, chalk 13,000 Black; looks like graphite 13,000 Absorbed oil 13,100 Pigmented. with oil and water 13,100 Graphite castor oil Hexachlorethane 13,700 per cent solution soluble oil Red lead 13,700 Dry Mineral oil 14,200 Turbine oil Flowers 14,800 (B) Dry (B) signifies that cup broke during drawing 36—THE IRON AGE, June 13, 1940 that, general way, the same lubri cants appear high the order merit all three cases, and this fact reflected Table The principal exception this rule naphthalene, which gave good results with mild steel, fair results with brass, and poor results with aluminum. inspection showed the reason for this the surface the aluminum was clear that the naphthalene, which essentially solid lubricant, caused scoring the softer metal, while has such effect the harder the mild steel and comparatively little the surface the brass sheet. Hence, can only regarded satisfactory lubricant for relatively hard materials. proportional effect lubrica tion the punch loads different with the three metals. With mild steel, the best lubricant reduced the load from about 13,700 11,300 cent. With aluminum, the change from 3110 (or more, pressing broke this load) 1930 appears, therefore, that with intrinsically heavier drawing pressure, the absolute TABLE Lubrication Brass Sheet (64/36) Lubricant Punch load Anhydrous sodium soap ........ 9,500 White lead linseed oil 9,600 Graphite soluble oil 9,800 10,100 10,300 Naphthalene ................. 10,300 10,300 Metal polish (Brasso) 10,700 Steel draw water) .... 10,850 10,850 11,000 11,200 11,850 a / Dp \ | greater, but the proportional advan- tages less than with more readily plas- tic general inspection the results, and particularly Table will show that the most effective lubricants are almost all cases distinguished solid constituent. Pure liquids, even oils and liquids commonly used lubricants, not appear suited deep drawing under the con- ditions test. this connection should men- tioned that the process drawing un- der examination does not involve any significant degree ironing, and likely that under conditions where severe ironing occurs the results will different. The difference effect between good and inferior lubricants may then more marked, the condi- tions approximating more nearly those wire drawing. But for pur- ironing not serious factor. The behavior lubricants containing graphite was not altogether consistent. While graphite tallow formly good results, graphite soluble oil fell somewhat from grace with the brass sheet, Aquadag gave inferior re- TABLE Lubrication Aluminum Sheet (Normal-Rolled Soft) Maximum punch load, Lubricant Ib. Graphite soluble oil 1,930 Parax 1,950 Sodium soap (anhydrous) Graphite tallow 2,030 Beeswax turpentine 2,040 Tallow 2,230 Lanoline White lead P.S. compound Aquadag Steel draw water) 2,640 Grease (H.B.B.) Castordag Naphthalene benzene 3,000 (B) Cereclor (B) signifies that cup broke during drawing TABLE Summary Lubricants Lubricant Graphite tallow Parax Graphite soluble oil Anhydrous soap turpentine Tallow White lead linseed oil Dry graphite Lanoline Aquadag Naphthalene P.S. compound Mild Stee! Brass Aluminum poor sults with brass and aluminum, and Oildag gave poor results with all three metals. These curious disparities led the suggestion that the fineness and form the graphite itself might have some and through the good offices were obtained. These were tested the dry state with mild steel and brass blanks. was found that there were con- siderable variations between the punch loads for the different qualities, variations which were generally con- sistent between mild steel and brass, best results were given graph- ites form and those measured carbon content. The fine- ness the particles did not appear coarse, gritty impurities sensible the touch gave poor results. making use the comparisons bear mind the conditions under which the tests were made. The speed drawing was considerably lower than that normally adopted practice, and the temperature the apparatus not appreciably higher than that the laboratory. has been shown, for example, that the efficacy grease improves with speed pressing more than that graphite, and until tests have been made under speed and tem- perature conditions tive practice, certain element practical use the results. Welding Facilitates the principal difficulties cutting steel plates encountered clamping the plates together that the cut can readily started, espe- cially when small thin sheared plates are stacked. The fins and distortion caused shearing require heavy pressure C-clamps other clamp- ing means force them close enough together for starting and maintaining the cut. According Slater, Air Re- duction Sales Co., Boston, company his district having orders for large numbers small circular shapes steel solved the problem utilizing arc welding hold stacks Stack F