The Iron Age 1940-08-08: Vol 146 Iss 6

O AUGUST 1940 VOL. 146 NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager C.E.WRIGHT J.A.ROWAN_ T. W. LIPPERT Managing Editor News Editor Technical Editor Associate Editors Art Editor Editor Emeritus 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 HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis LEROY ALLISON Newark, N. J. Editorial One-Man Technical Articles What's New Finishing Feature Reports the Assembly Line Washington News News and Market Reports Scrap Market and Prices Fabricated District Market Reports Warehouse Machine Tool Activity Sales Possibilities Products Copyright, 1940, Company DIX, Manager Reader Service Advertising Staff Herman, Chilton Bldg., Philadelphia Hottenstein, Otis Bldg., Chicago Leonard, 100 East 42nd St., New York Pierce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York W.J. Fitzgerald Jf 28 P Bidg., Pittsburg Warren, Box 81, Hartford, Conn. Don Harner, 1595 Pacific Avenue Long Beach, Cal. Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. lished every Thursday. Subscription Price: United States and Possessions, Mexico, Cuba, $6.00: Canada, $8.50; Foreign, 312.00 year. Single copy, cents. Owned and Published CHILTON COMPANY Publication Editorial and Office Executive Offices Chestnut and 100 East 42nd St., Philade!phia, Pa. New York, U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Improved Heat Treating South 104 106 Here’s real showdown! Rent Flex- Arc. Easy obligation buy. Rental can applied against purchase price. IRON AGE, August 1940 RUNS. RUNNING BACK See your FlexArc dealer today and tell him you want make the FLEXARC 200-FOOT TEST. Then prepared for new thrill arc welding. Pre-set FlexArc’s one control—step away 200 feet, any distance you choose—and strike your arc. See what rock-steady arc FlexArc gives you. Note that there’s need return the welder for readjustments—either immediately after warm up, for different positions the rod. FlexArc controls the arc for you—perfectly, and automatically. Here’s the capacity lay metal faster than you ever did before—to spend seconds every minute welding, not walking—to make better welds because the arc always right. Isn’t that exactly what you want welder?... then try the 200-FOOT TEST. WESTINGHOUSE ELECTRIC MFG. CO. DEPT. 7-N EAST PITTSBURGH, PA. — 7 ay ff i ~ - Cape Cod last Thursday, happened pick The Iron Age marine engine repair plant. Even vacation shoe- maker sticks his and bussman rides the busses, seems. legitimate for editor read his paper under such circumstances. noted the editorial that issue and appreciate the kindly thought the president The Iron Age attempting bat for the editor during his absence. also noticed that threatened, rather should say promised, write another editorial this week while the editor was com- pleting his vacation. Such kindly intent must surely deserve appreciation and hereby tender thanks. But cannot permit our president sacrifice not speak our readers. When man needs dictionary and large type fill the scanty space left for message this page with one syllable words, surely evidence great travail mind and strain intellect. And our worthy president needs conserve what has. the editor interrupting his vacation among the black flies and mosquitoes carry on. will carry from where our president left off last week. said that The Iron Age for once, least, should agree with Presi- dent Roosevelt. And that since the President has stated that his dearest wish has been retire private life, should everything our power help him attain his desire. AUGUST 1940 suppose natural for president think terms giving other presidents what they want. But editor think that way. thinks terms giving people what they need, regardless presidents, capitalized otherwise. And conversely, keeping people from getting ESTABLISHED what will bad for them. 1855 Looking from this angle, believe that the worst thing that could happen this year unfortunate happenings would the up- setting the third term tradition. And would say the same thing Republican, bona fide Democrat, Prohibitionist were running for third term. Upsetting this precedent would bad enough ordinary times. But would infinitely worse these days when populations are suc- cumbing one-man rule. True, the President has evinced his belief that there other Democrat capable running the United States and, course, his opinion includes Willkie too. But Mr. Hitler thinks the same thing about Fuehrer Hitler, Mr. Mussolini about Duce Mussolini, and Mr. Stalin about Com- rade Stalin. That the outstanding symptom dictatorship the superiority complex. are now doing most the things that have been foreign our ideas and ideals Americans. are arming the teeth; are raising huge army conscription time peace, and are prepar- ing tax future generations into the poor house. Perhaps that neces- sary, but third term not. And defeating the third term, one-man idea, the only out have left prevent from becoming totalitarians and restore our liberties after the war over. | € 2 oO ) 0) Sheet Forming and Fabrication Costs Reduced! Many manufacturers are cutting production costs, making finer products, and beating competition with Inland special sheets and strip. They get these results be- cause Inland metallurgists determine the kind sheets best suited their purpose —and, then work with the mill produce the exact sheet specified. Users Inland Sheets can definitely count superior forming qualities, constant uni- formity, and fewer rejects, from beginning end production runs. Inland metallurgists, with their perience, will also pleased help you developing tailor-made sheet strip that will lower costs and improve your fin- ished product. This Inland service yours for the asking—without cost obligation. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS Detroit, St. Paul, Louis, Kansas City, Cincinnati : } vat - onym for centrifugal casting, the foundry process which the only radical change the casting metals since pressure die casting was introduced. Reduced its sim- plest definition, centrifugal casting may described the casting metal under pressure the centrifu- gal force developed through high rota- tive speeds prepared mold. The centrifugal casting process not new; was conceived about 1850 but was not until after 1900. However, because the special equipment required and the difficulties attendant the process, was not widely used for bronze and alloy steel until recently. Within the last three years, the number firms capable casting centrifugally has quadrupled, partly because competitive situation within the foun- dry industry, but mainly because IG. gen- eral view the Ampco Metal, Inc., centrifugal casting division, showing four the small casting spindles well part the melt- ing equipment used this divi- sion. —The Process, Its Limitations and Advantages ZAISER Metal, Inc., Milwaukee industrial acceptance and demand for metals cast. Process Basically Simple Unfortunately, not possible outline given set conditions given procedure for the Therefore, this article must neces- sity confined somewhat gen- eral description the process and the benefits derived therefrom. Prac- tice will necessarily vary, dependent upon the metal being cast, the size ay j ay f = 2—As-cast, semi-finished, and completely machined controllable pitch propeller bushings. These are all made special aluminum bronze. the casting, and special features the The requirement for me- chanical equipment capable wide variation (from 3000 done), which can affixed mold die for use actual production. Mechanical drives are although most the machines (see Fig. are hydraulically chosen for among which were infinite convenience remote control cen- spindles, and the cushioning effect hydraulic power against shocks, together with the elimination high-speed gearing requirements One drive pump takes care five spindles centrifugal machines, and the hook-up made that from one five machines can operated simultaneously, the same differ- ing speeds. This system, which has been constant use for over months date, has proved entirely satisfactory. Mold equipment varies widely, de- pendent upon the design construc- tion basic equipment, and the type castings being produced. Most common steel iron shell, dy- namically balanced, with tures for attachment the driving unit. The mold, usually core sand composition variation thereof, rammed this liner and the whole unit baked core oven. some cases, the shell used 24—THE IRON AGE, August 1940 retainer only, and the liner baked then being slipped into for casting. mold such this suitable for the production only the sand liner broken production runs, steel molds are used, the inside contour which machined the desired outside contour the castings made. Compositions such molds will vary, made alloy cast irons the type usually used for billet tion. Production equipment type can used for from castings before redressing pieces have been made, redressing necessary, for heat cracks will have appeared the mold, its surface will have been roughened abraided, making casting removal difficult, and the castings themselves unsightly. Castings produced baked sand liner method require little, any, taper from one end the other, since the mold destroyed shakeout. With metal permanent dies, slight taper the order per ft. the diameter em- ployed, that the casting quickly frees itself for removal and does not wear the mold surface unduly. Pouring and Rotating Regardless the type mold cover placed over the end from which the liner inserted rammed up. Pouring the metal handled ways, the most 3—Typical centrifugally cast elevating and lead screw nuts, which are spun quantities ten several hundred per run. = | ” 7"D } | x 4 j } | N = MN | ' 3 —— a ! . | | common which pouring directly into the mold through hole this cover plate, which procedure ally wholly satisfactory for compara- tively short pieces. the making long thin-walled castings, this same procedure sometimes followed, but usually only when the mold inclined rather than fully horizontal. methods are used plants tative gear blanks which centrifu- gally cast. whereby the molten metal either poured along the whole length the casting means trough which can filled, inserted into the mold and then dumped, poured through retracting spout which the rear end the mold forward dur- ing pouring. Centrifugal castings made dies molds revolving about horizontal axis. However, opera- tion may either about fully verti- cal axis one which inclined some desired degree the horizontal. The choice usually governed the casting being produced well the limitations equipment hand. Long pipes and cylinders, for example, lend themselves best pro- duction about axis that horizon- tal nearly so, whereas short pieces such gear blanks, produced fully vertical machines. Rotative speeds during casting will, mentioned before, vary with the shape concerned, the speed need only enough hold the metal against the mold wall. the other end the scale, may reasoned that the speed rotation, the greater will the compacting and cleaning action due force. The factors cooling, shrink- age, hot metal strength, segregation metal ingredients must all considered establishing proper speeds, however, and these will all vary from one alloy an- other, the “cut and try” method fre- slide rule, with past experi- ence and case histories the guiding influence. Wide Variety Casting While true that not all shapes castings can made centrifugally, experience, improved equipment, and progress methods have greatly in- creased the range work that can inders bushings are, obviously, easiest produce and comprise the greatest overall centrifugally cast ton- nage. general sense any varia- tion this basic shape can pro- duced, the greatest limitation being that the inside diameter the cast- ing must either straight bore, one which can machined the required contour without too great machining cost metal loss, good propeller bushing, Fig. which some 40,000 have been produced date. Fig. illustrates typical elevat- ing and lead screw nuts now being spun quantities from ten several hundred per run, dies. Fig. shows representative gear blanks produced the same manner. example the range work being done, the weight parts being centrifugally cast bronze plant ranges from the 8500 Ib. and diameters vary from in. in. Intermediate these ranges the screw down nut shown Fig. Most Bronzes Are Cast Most copper-base alloys metals can cast centrifugally, although casting practice must often varied from one alloy another virtue Greatest problems sented so-called alloys which are reality mixtures, that the in- gredients not alloy one with the other. selves. The copper-lead series one such material. Lead and copper will not alloy, and virtue their differing specific gravities and melting points, metal containing these two ingredi- ents alone one the most difficult non-ferrous alloys produce. Cop- per-leads can centrifugally cast with THE IRON AGE, August | | ” | > = ¥ IG. 5—A screw down nut, centrifugally cast, for one the steel mills the Chicago district. close attention (1) chill effect that the rapidly and without time segregate into objec- tionable large particles; and (2) care- ful speed control, with sponding casting pressure) well below that which would used for produc- tion castings from true alloy. The spinning this type metal usually confined straight bushing exceeding in. Another alloy series which centrifugally cast the copper-tin- lead group, familiar example which 80-10-10, phosphor bronze. Inasmuch the presence tin makes this alloy rather than mixture, higher rotative speeds can Here the primary difficulty the hot-shortness the alloys, which tends cause the fissures cracks during the cast- ing operation, unless proper control speed, pouring temperature, and chill effect exercised. With this series, more complicated shapes used. and heavier wall sections can suc- cast. Alloys the bronze class are ideally suited tor centrifugal casting, the main precaution necessary being that composition must care- fully watched because the alumi- num losses which may abnormally high due excessive drossing caused turbulence the casting operation. 26—THE IRON AGE, August 1940 Hot strength and homogeneity the alloy are good, and chill effect great consequence; therefore, mold materials can chosen without par- ticular regard the requirements the itself, and speeds may freely used. Complica- ted castings and very heavy wall sec- tions can produced the aluminum bronzes. Many other alloys including manga- nese bronze, nickel bronze, beryllium copper, and monel metal are adapt- able centrifugal castings. Most these have certain peculiarities which must taken into account, but which can compensated for the basis casting experience. Advantages Process The advantages the centrifugal casting process are many. The greater demands made metals modern industry have some cases led distrust castings for heavily stressed parts because sometimes overemphasized fear casting de- fects. result, many parts have been made from forgings wrought 6—These sketches illustrate the chilling action sand and cen- trifugal castings. Upper left shows the directional grain flow the cooling sand casting, one produced statically, whereby chilling takes place from both inside and outside surfaces, leaving area weakness caused meeting the grain growths final solidification and the trapping impurities this juncture. The remaining three sketches show progressive formation grain centrifugal casting. Upper right illustrates the layering effect present immediately after pour- ing, with minute impurities distributed throughout the casting. Note (lower left) partial solidification from the outside surface inwards, with impurities concentrated the still molten metal near the inner diameter. The fully solidified casting (lower sound, and with weakened juncture caused qrain growth from inner and outer sur- faces. Impurities have all been forced from the body the metal itself and lie the inner bore, from which they are subsequently removed rough machining operation. > | | s is \ } a’ \ j j \ \ / j \ \ j \ the centrifugal casting spindles and method mounting retainers. ° ° ° mium paid the form metal waste illustrates this and other differences machining, and high machining centrifugal structure costs. That such parts, when suit with sand cast structure. able design, can made centrifugally definite saving vouched for stance, large motor company’s use this method for transmission clus- ter Many are changing gears, feed nuts, parts from sand centrifugal castings be- cause the assurance sound ma- terial and the consequent savings machining costs through eliminating only material but also machining time tive sand castings. The explanation for uniform sound ness spun castings simple Sand cast cylinders solidify progres- sivley from both outside surfaces. result the fact that minute impurities the metal are not trapped progressively this chill ing but tend travel ahead the solidifying crystals, any such impuri- ties are concentrated where the two grain growths meet. This phenome non true all statically cast metals, whether ferrous non-ferrous, and ceivable, for instance, that the case feed nut the base the nut The oxides most metals are lighter than the metal itself, are gases and possible non-metallic inclu- sions, such bits furnace lining, fire brick, similar materials that might present bath molten threads would lie this weakened Since centrifugal POURING large cen- metal freezes from the outside sur trifugal casting which tace only, there possibility the above condition occurring. Further more, centrifugal casting largely elim inates so-called columnar growth metal grain, breaking these columns into shorter, more having greater strength and homogeneity. Fig. metal. Skimming removes most those impurities, and provided freezing metal the mold does not take place too quickly, the balance tends float the top sur- face the casting displacement the liquid metal. centrifugal casting this weight dency multiplied many times and impurities are literally driven out. Stated mathematically, the ratio the force centrifugal separation o > where the distance the particle from the axis rotation (in feet) and the number revolutions per second. Taking example casting being made centrifugally 1000 r.p.m., and considering en- trapped oxide particle in. from the axis rotation, found that this the small cen- trifugal casting spin- taken during rotation while the metal solidify- ing. particle driven from the body the casting force 110 times that which would exist sand casting. wonder the process has been called liquid forging! While the effect this multiplied THE IRON AGE, August 1940—27 = 4 cast (left) aluminum bronze—about per cent copper, aluminum, and 3.7 iron; some analysis centrifugally cast (right). Note the smaller particle size and extremely even distribution for the spun casting. diameters. cast (left) standard manganese bronze. The same material centrifugally cast (right) shows both the grain and particle size greatly refined. diameters. cast (left) manganese bronze the high tensile variety; same material centrifugally cast (right). Difference grain size particularly evident. 100 diameters. 28—THE IRON AGE, August 1940 ties the resultant casting defi- nitely favorable, not great might general, tensile and yield strengths the metal are raised from per cent, ness remains approximately the same except alloys affected chill action, ly. greatest and tant effect from the point, lies the the properties castings, for spinning does assure uniformity difficult obtain static castings. What Are Costs? centrifugal casting, the inside impurities, has been seen. These are removed rough machining operation before the rough castings are shipped, the cost that operation just about balancing the saving fected through obviating the necessity pouring extra metal for gate and riser purposes. The cost centrifu- gal castings, therefore, cases more less predicated the quantity required, since setup charges for make-ready operations are covered the per-pound price the castings ordered. said that when more castings are required, the cost thereof the customer little, any, more than for sand castings. There are, course, many exceptions the above statement; while does not any means hold true all alloys, all types castings will furnish clue least the general picture specially-shaped pieces, such gear blanks flanged bushings, mold charge necessarily made. That charge, borne the customer, com- paratively minor, being the aver- age about per cent the cost comparable forging die. The manu- facturer thereafter bility for maintenance the mold, which becomes his property. This, then, the general summary the centrifugal casting process, and while all the procedures outlined above are not universal, due diversity practice and facilities various plants emploving the process, the picture essentially outlined. Spun castings will continue gain popularity, and not doubted that the next five years will see wide general use the process and wide recognition the place dustry. Boondoggling Defense ° COL. TOULMIN, Jr. THREE previous issues THE IRON AGE, Colonel Toulmin has discussed necessary mental and industrial alterations necessary for the adequate pro- tection the United States, with one article devoted entirely the strategic problems involved. Herein, attention directed specific military and indus- trial problems necessary for adequate air protection. Colonel ability for treating this problem best expressed quotation from citation Mason Patrick, Major-General, S., A., Chief Air Service, France, Oct. 17, 1918: take this opportunity express you and place record earnest commendation for the work which you have done Chief Coordination Staff. this task you brought understanding its magnitude, the ability and un- tiring energy necessary for its accomplishment. Your work has been well are losing value and effi- ciency the allied armies through lack coordina- tion and Lloyd George, April Lack planning, vision, and co- ordination the political high mand going wreck the 50,000 plane program just the 10,000 plane program was wrecked 1918. early 1917 was announced that planes—a number those days com- parable relatively 50,000 planes today. 1917 1940 great deed, some the very companies then operating produce this magic number great fleet ships are the companies now expected, with sim- same ballvhoo magic. What was the practical results? The writer can speak from personal ex- perience because when the reorganiza- tion the United States Army Air Corps France May, 1918, was taken over, his plan reorganization was adopted correct the conditions which that month the United States Army had 35,000 men and cers overseas, but squadrons active the front. All this after months political planless talk and military The Air Service the was completely and thoroughly disorgan- ized for lack business organization ° and had American ships fly despite the expenditure the United States nearly bil- lion dollars. had comprehensive and operable plan coordination and mobilization. There was not single United States plane France the 10,000 that were glibly promised near- months before. Within six weeks taking over the management and reorganization the United States Army Air Corps Europe Chief the Coordination Staff, the writer was able put the squadrons the front support the ground army. When the war ter- minated November, there were more than squadrons operating the front with complete supporting organizations ready put 219 squad- rons the air the spring 1919. There were 70,000 men the field. Over 9000 airplanes had been bought France and England, and the most ever secured from the United States was 623 DeHavilands October and November, 1918. They had completely rebuilt France, both engines and plane structures, be- fore they could flown with safety. That was the sum and substance nearly two the ballyhoo ships. making the Army Air Corps or- ganization work, Coordination Staff and Strategic Staff were organized. real mobilization plan was put into THE IRON AGE, August | { { >, | ; } 2 ve ° ° } ° a | | | | : | | | \ A | we wee. 4 | q OPERA- STRAT- TIONS EGY SECRETARY FOR AIR NAVY MATERIEL PRODUCTION ASSISTANT SECRETARY AIR CHIEF STAFF AIR COMMANDER ASSISTANT SECRETARY MILITARY OPERATIONS AIR GENERAL STAFF AIR GENERAL STAFF WITH AIR FORCE CHIEF TECHNICAL STAFF WITH AIR FORCE AIR ARMY immediately get the mate- rials and men together operate the front. Under the great leadership General William Mitchell, those squadrons were operated with the army most effective manner. the battle Saint Mihiel, General Mitchell had under his command the largest group airplanes ever assem- bled single battle that time —500 planes France, England, and the United States. putting vision and organization the United States Army Air Corps was made function within few weeks after its management was taken over. This was done without chang- ing single officer man, without firing anybody, but putting into the proposition the same sort executive ability, vision and organization that any responsible organization would re- quire. Now consider .the present situation —50,000 ships are just meaningless expense, unless the army command again revitalized. First and foremost Secretary Air with Assistant Secretaries are needed, charge matériel procurement and military op- IRON AGE, August 1940 erations The organiza tion and military problems han dling this army are far more than anything ever attempted the United States any other tion. The order ability necessary for the creation, organization, man- agement and application this force war requires type ability far beyond anything that has been demon- strated displayed the United States Army today. New Organization Needed Consider next what really needed this new army organization the air. Also keep mind that many the same types military minds now the regular army are like those Mitchell because had the courage and the patriotism point out this country just exactly what hap- pening today. there were justice, the men who court martialed Mitchell should today court martialed them- selves. This spiteful and disgraceful repudiation brave and great sol- dier, who also combined with his mili- tary qualities moral courage, wisdom and vision, will remain forever blot upon the history the United States. Now keep mind that danger for this country from this bound type mind military point view, based upon the old idea looking backwards past wars judge the future. This type mind has been trying manage the new air corps and will manage henceforth unless checked. Also, should kept mind that present danger comes also from de- fective political management military arm. The country suffer- ing from epidemic planless talk. this same hidebound type mind and reactionary military point view based upon the old idea looking backwards past judge future conflicts that has been trying manage the new air corps and plan for the air army the fu- ture. Consider now the record this the last five years very gener- ous treatment has been accorded the air corps. What kind ships were The Chief Air Corps now admits that fast ships were se- cured capable quantity production able contracts for aircraft manufac- turers. However, they lacked power, armor, flame proof gasoline tanks and cannons. the uninformed public the excuse that these deficien- cies were just discovered reason good. Such excuse was less the air into which spoken. Any competent second lieu- tenant should have had brains enough have anticipated each one these factors because they were common knowledge and record the Army Air Corps 1918 and since then. There nothing new about any them. The with this armor problem 1918 France, and even then the trend was definitely toward the use armor. The problem puncture proof and shatter-proof gasoline tanks which could not set fire incendiary bullets was solved. Also, mm. can- nons were successfully developed and mounted ships. common knowl- edge that speed only one factor airplane: the primary armament and fire power because ship made primarily hit and, secondarily, maneuver get away. All these data have been recorded the War Department files since 1918 and probably before. For the Chief | |_| | | — | | | G.H.Q . | |_| | Air Corps come before Congress now and admit that many millions dollars spent aircraft produced nothing more than racing ships, with millions spent such experimental gadgets, sufficient condemnation the brains and ability the air ser- vice Such admission should have been for prompt remedy the Secretary War through complete reorganization the air corps man- agement. The truth the matter that for many years the army corps has been more interested en- gineering types and changes, the con- stant change absurd manufacturing tolerances, and the maintenances speed records and other sporting events rather than doing the hard, tough prosaic work building com- bat ships heavy striking power that can get military results. This same management night reduce the cost aircraft not less than per cent and double the production aircraft with pres- reduction manufacturing tolerances. Aircraft now being built the basis automobile last four five years. slightest experience with air corps work knows that most ships last longer than the average pilot’s life. Most European nations experience figure that hr. the air all that ship may will per- mitted do. Therefore, there point the most meticulous refine- ment and accuracy with absurd toler- ances for the most elaborate ture. Most this comes from the effort the army make the results its appropriations last long possible peace time. Producing for war fighting ships quite another matter. the Air Corps command had been its toes, could have remedied the situation. the old story the army requiring which hamper the production mu- nitions and which makes them slow production. Then the army blames the manufacturers. Here where forceful and well informed Secretary for Air, with good staff, can put practical tolerances into the air program. Air Organization Necessary And now consider the third defect air corps thinking which been remedied yet. What kind organization FLYING PERSONNEL 50,000 men AEROPLANES REQUIRE ONE YEAR OTHER MILITARY PERSONNEL 250,000 men. AUXILIARY INDUSTRY AIRCRAFT ACCESSORIES FUEL EACH TRUCK 50.000 PERSONNEL REQUIRED BUILD, MAINTAIN, AND FLY WARTIME AIR FORCE WITH PERMANENT BASIC STRENGTH 26,000 AIRPLANES (This chart, reproduced here from article appearing the April 1940, issue The Aeroplane (London), illustrates graphically the personnel requirements air force 13,000 combat planes and 13,000 combat craft all-metal construction and average gross weight 10,000 The total replacements wartime would require least 117,000 airplanes and 221,000 engine units maintain the asic strength. shown, the man-power used the aircraft and accessories industry for re- search and the industries should the future army the air have? The words “army the air” are significant—that exactly what required. must not mere hand-maiden and back stairs servant the ground troops the navy. The success Germany not due its large number planes its efficient manufacture. due the fact that the army organization and command the air separate and independent, created for and purpose taking advantage the peculiar striking offensive powers this arm. The first conception must that this “army the air” fully capable and itself completely perform all the functions reconnaissance, attack, artillery fires, taking and hold- ing the ground and the supply the air corps completely from the air. Until this engendered the army air command, there will not real army the air take advantage these 50,000 planes. For instance, these dive bombers, light and heavy bombers and torpedo planes are The swift recon- naissance and attack ships constitute the cavalry and shock troops, the mechanized cavalry the air. Para- chute troops transport planes for engines, propellers, and instruments, and the other part auxiliary the production fuél, lubricants, uniforms, and their distribution and transport.) infantry, artillery and tanks constitute the infantry the air. Reconnaissance planes and artillery fire control planes, with their signal and communication systems, constitute the signal corps the air. Ground strafing planes and pursuit attack ships shock attack troops the air. The huge transport ships must able transport food, gasoline, munitions, water, engineering tools and similar impedimenta army, constituting the trains the air. This equipment can landed either chute. There must flying machine shops, flying ordnance shops, and fly- ing airdrome gyro repair shops, capa- ble alighting airdromes that have been destroyed, with adequate engineer equipment aboard restore those air- dromes for other types ships that they can land. The latter type ship will probably the helicopter type like the autogiro. will designed that can land with equipment limited areas fields that have been destroyed bombarding explosion can repaired for the fast landing pursuit ships and bombers the main air force. other words, the army the air with 50,000 planes must THE IRON AGE, August | | ‘ | i | ; ij ‘ | | = | vine it | complete and self contained any other army. must just inde- pendent ground troops the land army has been the past, before 1914, air troops. the most important thing this army organization the air needs this: separate independent general staff and army command. quired power imagination and con- ception the organization, manage- ment and direction “air army” vastly different from the concep- tions the ground military organiza- tions that necessary and essential that this general staff and command entirely independent the regular army’s general staff. This does not mean that the high command the regular not coordinate its operations with that the army with the operations the land and naval forces. does mean that this army the air requires such highly specialized organization with 50,000 ships, that the complete air or- ganization will demand general staff larger and more effective present staff have for the small regular army. 1927 “Air Service, the author wrote ing prediction what the United States Army should have for its army the air: “(a) That the Air Service should have complete plan organ- ization, mobilization, and supply for immediate use the United States and foreign areas possible operation, which all the details are completely work- out for immediate execution. “(b) That the Air Service should have staff its own addi- tion its General Staff rep- resentation and affiliations. “(c) That plan necessary for maintaining manufacturing sources alive for future air sup- plies. “(d) That aircraft armament should made, furnished, and repaired under system which the Air Service should have the final ap- proval. There should divided authority. “(e) That the Air Service should training its men and officers and the temporary education ground troops promote that close understanding between the air and the ground essential for army’s success. “(f) That separate premotion list course essential, with ade- quate compensation for the ex- tra hazards time peace, personnel and maintain morale. 32—THE IRON AGE, August 1940 “(g) That great system supply depots, repair shops, dumps, and the like must worked out complete detail and tested suf- cessful working. That study should con- tinued the new strategy and tactics the air, our schools the Staff and Command now provide for the ground.” These predictions 1927 are amply confirmed the events 1939 and assuming that 50,000 planes are available (the allied armies had 22,000 operating the counts the vision and organization this force take full account its effectiveness. This brings the author the final statement. What the United States Army lacks lacks this plan for both the ground troops and for the air corps. This not cism the regular army, but criticism the political components the government which have plunged into this great maelstrom produc- tion equipment mech- anized and motorized equipments and planes without having and definite military plan operation mind. Generalities are for such equipment must de- signed and organized for specific pur- poses. the country have “Over Seas Command” such was set forth tive the chain islands along the Atlantic and Pacific coasts? country organized for expedi- tions requiring landing parties? there attempted the old-fashioned landings the force going make landing air foreign coasts just the Germans have done, but only more extensively and effectively The era marine corps landings, efficient they are sea, will over. Such landings are more pos- sible against organized resistance than the marchings the legions Fred- erick the Great close massed forma- tions would feasible today with ground armies. Such land- ings are all right against disorganized forces South American countries tacks because political disturbances, but they are silly and futile things defend itself. These great motorized anized forces the ground, the au- thor predicts, are but transient phase the new few years they will obsolete foot troops, marching from place place foot Such mechanized equipment will all long ground treks will over except for mopping purposes. But return the plan, organizing for expedi- tions into Mexico and South America South America further organizing take the ing for attack upon Japanese main- caught like rats traps was the French army the Maginot line? going provide system alterna- tive landing fields and means pairing landing fields that matter what damage done the air corps bases, ‘it will able ship new and repair the old between sun- down and sundown? These and other countless questions are necessary determined before the country can plunge into this great mass commit- ment all its resources certain kinds equipment. This leads the final conclusion. When great armed force from 1,000,000 army the mechanized and motorized and army the air with 50,000 planes and mil- lion million and half men operate them them, the country has gone the limits any one department coordinate with another department voluntarily. Command and Defense Cabinet Min- ister coordinate these three branches the service and the supply all three branches through the National Defense. Here must lo- cated the master mind and the direct- ing agencies for the coordination these forces with and operations staffs. Here again Germany the wisdom upon which she has based her success having this unitary command. Wherever the operations are purely land purely naval, the respective commanders are mand, But where necessary coordinate all three forces, there appointed supreme commander who can coordinate them and give the or- ders. Nothing left acquiescence, cooperation internal politics the ‘ | | | | ivets into little slots wheel and drop oft the perimeter into sorting boxes. They BELOW are segregated first diameter, then HIS little hand op- head (universal counter- erated machine sep- and finally length. But since arates roundhead and flathead rivets high speed, relieving the length sorter the and odd shapes metal, elec- burden first passed over this col- lection, snatching out the extraneous ° rivers are ° e Ib. 5/32 in. rivets rivets some 150 differen hr. kinds which are passed through the sorting machines shown. the floor sweepings comprise, besides the rivets, mass screws, bolts and sorting machine. the rivets travel, heads up, along the incline track from the feeding hopper, they ride into teeth cut into the perimeter the big wheel and are carried around until they strike their re- spective length ganes and are knocked off into bins. ° ° LEVER rivet sorting machinery will lop off around $12,500 maker the well Bombers and Flying Clippers. Long decided was cheaper forget about aluminum dropped the floor than have riveters take time out recover them, espe- pected drive rivets day FTER the steel bolts and nuts Nevertheless, rivets swept have been picked out the day, per were not sweepings electromagnet, the ignored, team youths was aluminum rivets are first shaken through series sifters which set work sorting them them diameter. They were not even able pay their Way. Then went out the tool design department. The chines pictured here were designed and built the plant. result, the heterogeneous collection rivets clat- ter down track from hopper, click | | | | | AD : =f AST week the author de- scribed stress raisers and the effects notches static tension, etc. Herein, concluding this correlated abstract, Mr. Sachs describes the effect notches im- pact bending, and the im- pact characteristics vari- ous steels. All these data are particularly timely view the many products now being made which must not fail service. tered cubic and the hexagonal close- packed arrangements. The majority metals, such nickel, copper, alu- minum, silver and gold have centered cubic crystal All these metals and many their al- loys are very ductile even the lowest temperatures that have the present time. Only the very high melting members face-centered cubic class, iridium and rhodium, become rather brittle tem- peratures the usual working range the other all the remaining metals are more less brittle temperatures which are low comparison with the melting points. This particularly true the metals have coarse grain size. under certain conditions because brittleness room temperature. This statement also applies the close-packed metals—magnesium, zine, and spite their rela- tively low melting points. other metals have more complicated crystal structures and are only ductile tem- peratures approaching their points—except tin, which very tile room temperature, but also comes brittle subjected impact low such iron, tungsten denum, offer BENDING: extensive literature deals with the notched har impact bending test. However, confusion rather prevalent the practical and academic meaning the results obtained this test, which 120 measures the energy that metals will absorb under rapidly applied force FIG. effect The unique position this test based the phenomenon that all fer- ritic steels break brittle tested sufficiently low temperature (See Figs. 11-14). the contrary, many other metals, including the austenitic steels (See Fig. 13), not become brittle all impact tests,“ even ex- tremely low temperatures. the fillet radius the impact strength bon and nickel various tempera- tures. (Arm- strong-Gagne- bin.) Impact energy absorbed (Charpy), stricted the notched bar impact test. All ferritic steels also break brittle tested static tension very low temperatures, while non-ferrous met- als and austenitic steels become slightly stronger with reducing without losing their Thus (see Fig. 15), carbon steels commercial polycrystalline condition have been found become brittle tension tests the testing temperature lowered far —330 deg. (—200 deg. C.). This fundamen- tal characteristic the iron crystals, lographic gliding be- low —240 deg. (—150 deg. C.) but -280 -240 -200 -80 -40 Temperature testing, deg. Temperature deg.C worked Hot rolled ° ° ° FIG. w energy ab- sorbed notched bar im- pact tests vari- ous temperatures different types mild steel the hot rolled and nN Impact energy absorbed (Charpy), much the same manner other brittle material, such rock cold worked con- salt antimony. dition. The effect temperature the 100 200 300 400 100 200 closely correlated with their crystal structure. Most pure metals crystal- lize the three simple lattice the face-centered cubic, the body-cen- 34—THE IRON AGE, August 1940 | 160 | . | y ” | | | ° yu fj | . Impact energy absorbed (Charpy) The particular importance the notched bar impact test based the phenomenon, that the temperature which any steel becomes raised the two factors which pri- marily characterizes this test and dis- tinguish from the more common static tests, the high speed testing and the notching. has been ob- served, for example,” that malized 0.25 per cent (See Fig. 16) exhibits carbon low impact value and brittle break (with spe- -300 -200 Temperature testing, deg. * Coarse grained in the conditions (b) and (c) FIG. MPACT characteristics various steels, according experiments Herzig and Parke, the effects carbon content, alloy and heat treatment: (a) normalized; (b) heat treated 200 (c) heat treated 300 Brinell. cific notch) below the freezing point, while this “critical impact temperature” lowered ap- proximately —20 deg. (—40 deg. C.) static notched bar bending test and —240 deg. (—150 deg. C.) impact bending test cylindrical bar. Thus, the notching considerably more effective raising the critical temperature and increasing the danger brittle break than the velocity testing.” However, both factors acting simultaneously form steel that appears ductile down temperature about —330 deg. (—200 deg. C.), tested static tension bending, into condition temperatures the The efficiency notch this re- spect again depends upon its sharpness (see 11). The critical tempera- GEORGE SACHS Case School Applied Science, Cleveland ture 0.15 per cent carbon steel may high +10 deg. (—15 deg. C.) using impact specimens with sharp notch having fillet radius 0.009 in. while low —200 deg. (—130 deg. C.) the fillet radius in.” With per cent nickel steel, the corresponding critical temperatures are —60 deg. (—50 deg. C.) and lower than —310 deg. (—190 deg. C.). Another factor the procedure testing” which raises the critical im- pact temperature increasing breadth the specimens. increase the total dimensions the speci- breaks have been observed notched test bars 4x4 in. cross-section, while smaller test bars machined from the same material ductile with reducing dimensions the test bar, all conditions being ob- served maintain precise geometrical This explains the occa- sionally reported observations that the regular notched bar fails reveal brittle break for large piece that had failed brittle manner service. Impact Characteristics decisive improvement the low temperature impact characteristics low carbon steels (carbon under about 0.40 per cent) obtained proper steels possess lower critical temperature than rimmed steels, and thoroughly killed steels definite amounts aluminum solution ap- pear retain their impact toughness temperatures about 100 deg. (55 C.) lower than non-deoxidized steels (see Fig. 12). the other hand, Bessemer that rich non-metallic impurities such oxy- gen, nitrogen, phosphorus and sulphur, has been found particularly sus- ceptible brittle breaks and pos- sess critical temperature. Fail- ures Bessemer steel structures low temneratures have been reported. The critical temperature any steel further raised cold work and the subsequent strain room temperature short time THE IRON AGE, August 1940—35 125 | i= | | / | 4 (c) eo 100 a Annealed Reduction area stress eral stainless steels various temperatures. FIG. ABOVE erties some carbon steels different temper- atures. (Goerens and -10 FIG. LEFT NERGY ob. per cent carbon steel various bending tests different temper- atures both the the condition. Temperature | | Temperature IRON AGE, August treatment elevated galvanizing, nounced with insufficiently impure steels than with the thorough- have been recently developed. specimen decidedly influences the crit- ical temperature. surface the machined specimens are cold-worked condition, polishing plus annealing the critical temperature unnotched specimens per cent carbon Additional cold working the surface shot blasting rolling, the other hand, increases deg. (35 deg. deg. C.). Carburizing the surface low car- the tendency develop tures unnotched impact specimens, The type heat treating another that affects considerably the critical temperature steel. The fact that hardened steel becomes ever, little fundamental information available this subject. Overheating also the impact toughness normalized 0.25 per cent carbon steel overheated, such 2000 deg. (1100 deg. the crit- ical temperature raised normalized condition (see 16). ¥ 9, This holds true for any type test- ing, notched impact, static notched bar bending, and impact bending cylindrical bar. Steels the heat treated condition (see Fig. 13) are generally superior the normalized metal regarding the low temperature impact Heat treated carbon and low alloyed steels containing 0.15 0.45 per cent carbon have been found, quenched and tempered hardness 200 Brinell units, retain their impact toughness particularly low temper- atures, and lower temperatures than the same steel when heat treated 300 Brinell (see Fig. 13). The nor- malized condition shows usually the impact temperature for each particular composition. The critical impact temperature carbon and alloy steels increases with increasing carbon content (see Fig. 13), while alloy steels are generally superior similarly treated carbon steels regarding their low temperature impact properties. Many elements are valuable small percentages alloy- ing additions this respect, such zirconium, vanadium, chromium plus (see Fig. 11), and combination with molybdenum.” Aus- tenitic alloys, possessing the cubic face-centered crystal lattice not become brittle all low tem- peratures (see Fig. 14), already mentioned. Thus, austenitic stainless steels are suitable without restriction for low temperature