The Iron Age 1940-09-05: Vol 146 Iss 10

SEPTEMBER VOL. 146 NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing News Editor Technical Associate Editors F. J. OLIVER W.A. PHAIR G. RICCIARDI! 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 Nework, N. J. Editorial Technical Articles Arc Welding Steel Gear Blanks Cut with Rebuilding Worn Cast Iron Surfaces Feature Reports News and Market Reports News Industry. Machine Tool 100 Obituaries Scrap Market and Metal Working Activity Construction 104 Comparison Prices Iron and Steel Prices Summary the Week Ferroalloys, Pig Iron Prices. The Industrial Pace Warehouse Prices District Market Reports Sales Possibilities Fatigue Products Advertised Index Advertisers Copyright, 1940, Chilton Company DIX, Manager Rea Service Owned and Published CHILTON COMPANY (Incorporated) Advertising Staff Publication Editorial and son Findley Union Bldg., Cleveland Office Executive Offices Chestnut and 100 East 42nd St., Hermon, Chilton Philadelphia Philadelphia, Pa. New York, Hottenstein, Otis Bldg., Chicago U.S.A. U.S.A. Leonard, East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit 310 Ober, 100 East 42nd New York W. B. Robinson \ Fitzgerald OFFICERS AND DIRECTORS Warren, Box Hartford, Conn. MUSSELMAN, President Don Harner, Pacific Avenue JOS. HILDRETH, Vice-President Beach. GEORGE GRIFFITHS, Vice-President the Industrial Arts Index. Pub- WILLIAM BARBER, Treasurer lished JOHN BLAIR MOFFETT, Secretary United States ossessions, Mexico, Cuba, HARRY DUFFY CHARLES HEALE 428 Park Pittsburgh Single copy, cents. Dustless and Sliverless Wire.......................... 4 | Spectrographic Analysis Lead and Its Pipes and Fittings Carbon and Causes Gray Iron Casting Robe RENT FLEXARC AND GIVE ON-THE-JOB TEST Here’s real showdown! Rent FlexArc—see how stacks your hands, your job. Easy terms—no obligation buy. Rental can applied against purchase price. THEN MOVE THE Jog AND For 200 feet similar long cable runs running back Stop today any Westinghouse dealer’s and make the FLEXARC 200-FOOT TEST. It’s revelation what you can with modern FlexArc Welder. Just pre-set FlexArc’s ONE control—walk off 200 feet, more, the job—and weld. Watch FlexArc give you automatically the exact arc you need for any position the rod—downhand, vertical, overhead, all quick succession. Note how current readjustments after warm are un- necessary—how you never have chase back the machine whether you weld for five minutes five hours. Consider what these features can mean you —ability lay down more metal per hour than you ever did before—no lost time walking back the machine—better welds because the arc’s always right. agree—it pays make the FLEXARC 200-FOOT TEST before you buy any welder! WESTINGHOUSE ELECTRIC MFG. CO. DEPT. 7-N EAST PITTSBURGH, PA. J-21067 ELECTRIC —. . . am 5 4 Sees q a, 28—THE IRON AGE, September 1940 SEPTEMBER ESTABLISHED 1855 Creation Reverse the account the creation the world, you will note that the groundwork was done advance the final introduction Adam and Eve. First came the creation day and night; then the firmament; then the land and the water; then the vegetable kingdom; then the whales and fishes; then the animal kingdom cattle and beasts and finally man. That the sensible way about any creative job. first things first. Our armament program headed for trouble because the hysterical drive make for long neglect preparedness, effort being put upon last things the neglect first things. And that work. Orders placed for munitions not mean thing unless firm foundation has been made upon which deliveries—in time—can assured. Man, the end product creation, could not appear and survive until foun- dation had been built for him the way land, sea and firmament. Airplanes, tanks, guns and shells require similar preparatory foundation the form machine tools, small tools and gages. expanding munition program, capa- city produce these indispensable means production must increased step with increased munition expectations, but must precede them from three six months least. Reliable estimates our machine and small tool requirements show that 1941 capacity and output these prerequisites must stepped fully per cent. Gages essential making and inspecting must stepped least 100 per cent. And the time step them now, from three six months advance the munitions order.” You can have brick house “on order” from now until doomsday, but won't built until you get the bricks. not get the idea that the machine tool builders have not done remark- able job increasing output. This year the industry will produce collectively $400,000,000 worth products. This compares with output $200,000,000 1939. Plants now, general are running three shifts and maximum capacity. But that not enough. will need output $600,000,000 1941 keep pace with the munition program. This means that new machine tool and gage plant capacity must added cost possibly $200,000,000. This needed extra capacity not being built fast enough, first because the industry whole the money, second because hasn't firm orders which proceed this scale inviting public financing, third because already overexpanded and does not have amortization protec- tion against still more investment required. Machine tool builders not get the bulk their business from Uncle Sam. Their orders trickle down them from hundreds concerns who have dealt with Uncle Sam, and who, unlike the tool builders have firm munition orders scale warranting plant expansion. This proceeding side the face emergency and itself will put the munition program from three six months behind where should be. Uncle Sam cannot course order direct all the specific machines that muni- tion makers will need next year. But Uncle Sam knows that per cent step-up this capacity absolutely essential. And can find some way provide safeguard which will enable the tool industry undertake this vitally needed ex- pansion. Perhaps the $200,000,000 allocated the President for use his discretion, part which now building houses for future munition workers could utilized for this purpose. That would indeed building the land, sea and firmament be- fore introducing Adam. > Sy & 2 Pa : 3 like the Inland 5-point plan cooperation structural work, because will save you time and money. offers you— Engineering assistance which often enables the designer make important savings the use steel. Suggestions Inland engineers and field men who fre- quently can point the way time and labor-saving shop methods. Practical cooperation planning for simplification field work. Deliveries that put Inland Steel where you want it, when you want it, from start finish each job. Rigid devotion the Inland standard quality. you have problem structural design, fabrication. con- struction, invite you talk over with Inland engineers. This cost-reducing engineering cooperation yours without obligation. Call write your nearest Inland office. RAILS TRACK ACCESSORIES and Structura Includes Cost-reducing Engineering Cooperation ervice Inland Floor Plate has the tural strength rolled steel. assures 4-way safety combined with long wear all floors, platforms, runways stairs. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING REINFORCING BARS 4 | —The effects stress raisers the fatigue strength metals and alloys. GEORGE SACHS Case School Applied Science, Cleveland majority service failures moving machinery caused fatigue. According earlier conceptions fatigue failure will encountered the stress cycles stay within certain limits, called the fatigue strength the metal. Numerous ex- tensive investigations have, therefore, carried out determine the fa- tigue strength values the commer- cially important metals and alloys un- der conditions. However, the may differ considerably which must applied laboratory tests obtain reproducible strength values. Thus, polished specimens are generally used determine the “reg- fatigue strength, but the values obtained this manner often have found much higher than those found when specimens are used which more closely approach service conditions. has been generally observed that the fatigue strength affected First two parts correlated abstract similar manner the following three Machined notches, (2) Corrosion, simultaneous with fatigue, and (3) Chafing. regular fatigue strength usu- ally improved both cold work and heat treatments which also increase the tensile strength the metal. This particularly true for the steels, the fatigue strength which for all conditions about per cent the tensile strength. (See Fig. 1.) There not much information available the effect different treatments the fatigue strength other alloy types; and there exists simple re- lation between strength and tensile strength except for steels. The fatigue strength cold worked and heat treated metals the presence stress raisers has been given particu- larly little attention yet. The close relation between the three types stress raisers not generally recognized vet. however, well known™ that notches, well corro- sion, reduce the conventional bending fatigue strength steels, the reduc- tion being greater the higher the ten- sile strength and the regular fatigue strength the steel (see Fig. 1). has been similarly observed that cylin- drical and prismatical specimens break under chafing action within the grips and low fatigue strength that depends little upon the tensile and regular fatigue strengths Thus any one these three special types fatigue, little benefit derived from alloying and heat treatment. This fact probably more gen- eral importance than has been recog- nized vet. Several instances have become rather famous which the replacement soft steels treated high strength steels resulted fatigue failures which have not been adequately explained yet. Applica- tions which alloying and heat treat- ment failed improve strength service are the piston rods (see Figs. and diesel driven ocean and wire for suspension the first case combina- tion stress raisers, such notch- ing, corrosion and residual stress was found exist. the latter case the presence chafing action may have contributed the failure. The analogy between the three types stress raisers also holds true for THE IRON AGE, September a Sy 4 a | = ° | ee and prismatic specimens) Gillett and Mack Wunderlich Tensile strength, 1000 Ib. in. ABOVE IG. effect different stress raisers the strength steel (Bullens, Battelle). the beneficial effect local plastic deformations the inherent location the fatigue fracture. Different processes such surface rolling, peen- ing and shot-blasting can used reduce the harmful effect any these stress raisers. This will dis- cussed later detail. Notched Specimens that comparatively small relation men depends upon two factors (see Fig. 4), first, the sharpness the notch—which can measured the stress peak calculated according the laws elasticity—and second, the na- ture and strength properties the Within specific group alloys, such the steels (see Fig. 1), the notch fatigue strength high strength 32—THE IRON AGE, September 1940 200 240 BELOW 2—Fatigue break diameter diesel engine piston rod, caused the simul- taneous action very low fatigue service sq. in.), the transverse bores, the corrosive ef- fect the coolant, and high residual stresses Ib. per sq. in.) steels almost constant and only small fraction the regular fatigue strength retained. Thus, benefit derived from alloying, heat treatment (see Fig. garding the fatigue properties high stress raisers are Comparing different alloys the same strength (see Fig. 4), the effect loys apparently slightly lower than steels. The fatigue strength copper, aluminum and magnesium al- loys, however, least twice much reduced specific notch that steel the same strength. The relative effects notches torsion and bending fatigue conform the magnitude the stress peak which, for specific notch, differ- 3—Longitudinal section diameter piston rod, showing the development fatigue cracks the transverse bores. Regular (Necked and Fresh water, |_| orro g ll | notch Ww Oo Reduction fatigue strength, Copper alloys Magnesium alloys Aluminum alloys Tensile per sq. in. ABOVE 1G. 4—Reduction bending fatigue strength steels and various metals ferent types (McAdam and RIGHT IG. 5—Reduction the bending and torsion fa- caused notches differ- ent types (McAdam and Clyne). ent torsion and For circumferential groove the stress con- centration factors due torsion and bending (or tension) respectively are: where depth notch, and radius fillet (notch ground). From this formula ductions torsion fatigue notch- ing may expected, ranging from two-thirds one-half the reduc- tions the bending fatigue. Actually (see Fig. ratios between 0.84 and 0.75 have been For transverse cylindrical hole, the theo- retical relation reverse, and tor- sion about four-thirds the notch effect bending may expected and has been actually observed (see Fig. has much less effect the torsion than the bending fatigue strength (see Fig. 5). bore 100 150 200 250 Tensile strength, 1000 Ib. per The effect notches the tension- compression fatigue strength proximately the same magnitude the effect notches the bending (6) fatigue strength. =) and > © Annealed Heated 0.1 The surface condition fatigue specimens has considerable influence the fatigue strength, particularly high strength steels. Rough ma- chining has notch effect correspond- ing about per cent the at- tainable maximum (see Fig. 4), while other types surface finishing have smaller high strength steels the type used for springs, possess particularly low fatigue strength values (about 20,000 lb. per sq. in.), due the combined effects surface irregularities, in- clusions, cracks and decarburization, as-rolled condition (without machining) may have considerably higher fatigue steels The effect notching appears increase with the section however, the regular fatigue strength generally also moves toward lower values the dimensions the speci- mens are increased. This particularly observed magnesium The relation between the regular fatigue and the notch fatigue strength not simple type. has been observed that cast and some cast aluminum possess little notch sensitivity and that coarse grain higher notch fatigue strength (see Fig. than stronger but fine grained The cast semi-steels, such used Ford, also appear superior wrought steels regarding the absolute value the notch fatigue steels Corrosion and Fatigue Strength Corrosion the metal prior the fatigue test acts fundamentally the same way mechanical The progressing reduction the fa- Preheated (950°C) from (820°C) 0.1 Cycles, millions 6—The effects tension and austenitic grain size the strength and the notch fatigue strength grained" 0.37 per cent carbon steel (Brophy). THE IRON AGE, September 1940—33 turned turned Filed Regular tigue strength with increasing time corrosion can attributed the gradual increasing sharpness the notch. The effect corrosion acting simul- taneously with the fatigue strain de- pends primarily upon the medium corrosion. This subject has been ex- tensively reviewed the The atmospheric action may already factor the fatigue some metals, many metals exhibit slight- higher fatigue strength values tested vacuum than tested Saline water has The corrosion fatigue strength obtained with fresh water ranges approximately high observed the presence the most severe types mechanical while the corrosion fatigue strength obtained with saline water generally considerably lower (see Fig. 1). The fatigue strength some cast aluminum alloys little affected simultaneous corrosion fresh water, while saline water causes reduction Corrosion has particularly damag- ing effect the fatigue strength lium bronze has corrosion fatigue steel, which not superior carbon steels this respect. The fatigue strength notched specimens with circular hole fur- ther reduced simultaneous corro- Ed. Note: Next week the author con- cludes this very correlated abstract discussing ef- fect surface working, 34—THE IRON AGE, September Bibliography Heat Treatment,” John Wiley Sons, Fourth Edition, 1938, Vol. 37. Gillett and Mack, Proc. Am. Soc. Test. Mat., Vol 24, pp. 476-546. Thum and Wunderlich, “Dauerbiegefestigkeit von Konstruk- tionsteilen Einspannungen, Naben- sitzen und aehnlichen Kraftangriffstel- Mitt. Techn. Hochschule Darm- stadt No. (1934); Zeit. Ver. Deut. Ing., Vol. (1983), pp. 851-853; Vol. (1934), pp. 825-824. Thum and Bautz, “Steigerung der Dauer- haltbarkeit von Formelementen durch Kaltverformung,” Mitt. Tech. Hoch- Darmstadt, No. (1936). Sachs, Trans. Am. Soc. Metals, Vol. (1939), pp. 821-823. muth, Proc. Am. Soc. Test. Mat., Vol. 36, (1936) pp. 21-84. Res. Bureau Standards, Vol. (1934), pp. 527-572. Faulhaber, Buchholtz and (1933), pp. 1106-08. Lehr and Mailaender, Archiv. Eisenhuetten- wesen, Vol. (1935-36), pp. 31-35. Kuntze and Lubimoff, Archiv. Vol. (1936-37), pp. Karpov, Proc. Am. Soc. Civil Engrs., Vol. (1936), pp. 1128-1153. Boegehold, Metal Progress, Vol. 31, (1937), pp. 403-406. Koerber and Hempel, Mitt. Wilhelm Inst. Eisenforsch., Vol. (1939), pp.1-19. Hempel, Mitt. (1939). pp. 21-26: Arch. tenw., Vol. (1939), pp. 422-444. Proc. Inst. Automobile Engrs. Vol. (1937), pp. 821-896. Peterson, Proc. Am. Soc. Test. Materials, Vol. 32, pp. 413-420. Mills, and Steel Inst., Vol. 133 pp. 399-425. Trans. Soc. Mech. Engrs., Vol. (1936), pp. Trans. Am. Soc. Metals, Vol. (1937), pp. 229-244; THE IRON Vol. 145 (1940), No. 21, pp. 42-50. Appl. Mechanics, Vol (1936), pp. A90-98. Legierungen, 1939. Inglis, University Illinois Bulletin, Eng. Exp. Station, No. 164 (1927). Bandow, Deutsche Kraftfahrtfor- schung (1938); see Metals and Alloys, Sachs, Zeit. Ver. Ing., Vol. pp. 116-120. Ludvik and Krysto, Zeit. Ver. Ing., Vol. pp. 629-635. Brophy, Trans. Am. Soc, Metals, Vol. (1936), pp. 154-185. McAdam, Trans. Am. Inst. Mining Met. Engrs., Tech. Pub. No. Metals (London), Vol (1932), pp. 17-92. Moore, Metals Hand- book, 1939 Edition, pp. 147-153. Inst. Metals (London), Vol. pp. 93-122. 143-158. Sachs, Metals and Alloys, (1939), pp. Iron and Steel Inst. (1933), pp. Dolan, Eng. Exp. Sta., Univ. Bull., No. 293 (1937); Ap- plied Mechanics, Vol. (1938), pn. 141-148. Juenger, Mitt. Gutehoff- nungshuette, Vol. (1934) pp. RIGHT hydraulic press from rubber mill, became porous that had replaced, arc welding came the rescue. The bottom was cut out acetylene torch and replaced steel plate, arc welded into place. The job was done considerable saving the Menna Welding Co., Toledo, using G-E weld- ing equipment. x ABOVE large steel plant found that its sheet mill roll frame was badly worn, was repaired quickly arc welding. The mill was shut down Friday night, then dismantled, and the 41,000- cast steel housing was delivered the machine shop the Canadian Westinghouse Co. Saturday morning. Building the surface permit both the feet and bearing recess chined the original contours and size required 405 cu. in. weld metal weighing This was obtained from 160 Ib. down-hand welding electrodes, thus showing over-all deposit efficiency per cent the electrode used with the Flexarc welders. The was completed Saturday night and the frame was then handed over the machine shop. BELOW using arc welding fabricating device trunnion for rotary kiln, the Menna Welding Co. saved per cent the cost competitive article. The heavy parts were cut and shaped the Manu- Steel Supply Co., Toledo, and arc welded into the complete device shown here, using G-E 500- amp. welding transformer and W-24 electrodes. The trunnion made boiler plate steel in. thick, in. diameter, and weighs approximately 2500 THE IRON AGE, September 1940—35 ( ( } \ N \ ( | Dustless and Sliverless manufacturer electrical apparatus cannot take for him- self entire credit for having dis- covered the need smooth, sliver- less copper wire. Connecticut Yankee farmer expressed such need some years ago. wanted smooth copper wire from which make ring for his nose—the ring must not irritate and thus infuriate the bull. day, the copper industry has improved both the product and the method manufacture that may now cor- rectly state that has the answer the request expressed Burn- ham his excellent paper, “The Need Better Quality Copper Ap- paratus The steps taken arriving the 1Wire and Wire Products, October, 1937. Copper from Mine Mill,” Bassett, Wire and Wire Products, October, 1937, Vol. XII, 629. Used the Development Metals and Alloys, July, 1937, Vol. VIII, 185. me 36—THE IRON AGE, September 1940 Manager Metallurgical Development, Anaconda Wire Cable Co., Hastings-on-Hudson, present commercial development are follows: Sand scoured wire. Extruded rods. (4) Die scalped rods. (5) Double scalped copper. Bull ring wire. Bull ring wire was made cop- per wire bars which either forged hot rolled—followed single die drawing operation. The metal then was given relatively high atmosphere and quenched water. slivers, present, were quenching and subsequent acid clean- ing, were entirely 1890 this was standard product Wallace Sons, Ansonia, Conn., predecessor the American Brass ing the objectionable slivers, John Moody, superintendent the Ansonia plant the Coe Brass Co., invented sand scouring 1898, this opera- tion the defects such burrs, slivers, dust, ete., were pulled out the roots surface the magnet wire. The scouring the copper with sand was less expensive than the repeated open- fire annealing operations the bull ring process. The users the wire did not object the holes depres- sions the surface long the projecting defect, which would hazard electrical insulation, had 1906, the first was installed the Torrington plant the Coe the American Brass Co. means the extrusion press, was possible produce dustless, sliverless cop- per. copper billet was raised red heat and extruded into Co., forerunner IG. Details crinkled set surface stand- ard wire bar and scalped wire bar. One-fourth natural size. ° surface rod. That is, the heated billet was inserted cylinder and hydraulic pressure applied one end means cylindrical ram slightly smaller than the diameter the billet. the other end the extrusion the metal was forced through single multiple-hole die form the extruded rod. The outside surface the billet was shaved off during the extrusion operation. Therefore, any surface imperfections the original castings were entirely nated. This process was, however, too expensive adopted the users magnet wire. the Waterbury the American Brass another unique method producing dustless and sliverless wire was developed prior 1915 connection with the manu- phosphor bronze. This method was also used the for special alloys such Tobin bronze. order economically remove the original surface the brass, phosphor bronze, Tobin bronze, the rods were drawn through reversed sharp-faced die which peeled the surface. The method was success the custom ers for these materials were pay extra premium for perfect surface product. Double scalped copper, the term implies, material which ceived two scalping operations. First, the wire bar scalped remove the irregular set surface. This operation also removes the area oxide con centration that uniform structure the rod obtained throughout the entire section. the second scalping operation, the entire surface the hot rolled rod removed. Sur- face, dust, scale, and slivers are elimi- nated when the surface metal peeled from the rod means scalping die. The industry thus now has several ways which dustless, sliverless cop- per wire can produced: —The copper industry removes the entire original surface the metal meet exacting requirements appa- ratus manufacturers standard scalped wire bar can hot rolled, draw die scalped and drawn. (2) end-poured wire bar can hot rolled, draw die scalped and drawn. (3) Oxygen-free deoxidized high-con- ductivity wire bars can hot rolled, draw die scalped and drawn. cathodes can extruded into rod and drawn the required size. (5) Standard copper billets can ex- truded into rod and drawn. (6)Oxygen-free deoxidized, high-con- ductivity copper billets can extruded into rod and drawn. process for producing the dustless, sliverless copper wire will depend the economics the situation, and the exact requirements the appa- ratus manufacturer. Naturally, user copper wire cannot afford pay premium for special properties unless, actual service, can prove that will get longer life and con- tinued unfailing operation apparatus, During the initial development the electrical industry this country, was natural for the copper wire wire means obtaining the best available high quality magnet wire for these first successful dynamos. Some the electrical machinery manufacturers objected the cost the bull ring process but, the other hand, were not satisfied with the wire drawn from hot rolled rods. The or- wire contained slivers burrs sufficient magnitude create points concentrated electrical stress the insulation, thus causing early electri- cal failure and the 2—Typical examples surface noted when making laboratory bend tests 0.104-in. copper wire. diameters. THE IRON AGE, September 1940—37 - windings. Occasionally these defects would even wholly through the insulation. ratus have been continually increasing have likewise decreased the weight and size their apparatus. was natural, therefore, that expect the utmost from the insulation their magnet wire. speeds rotating apparatus have been increased which emphasize the vibration, and the concentration stresses surface imperfections re- sulting fatigue failures. These and other factors have contributed desire for quality superior sand scoured magnet wire. Manufacturers who have used less, sliverless, double-scalped copper stand and 3—(Left) section hot rolled rod with surface imperfections. (Right) Partial cross-section die scalped rod. Note smooth edge. Both diameters. are perfectly willing pay premium for this superior product. They find that the increased efficiency fully justify the use rods; not only their flat and square wire departments but also their wire, copper are based the uni- formity the original ings; the improvement rolled and the operations. The user copper wire familiar with the well-known set surface standard wire shows the typical standard cop- per wire bar, and also the appearance the wire bar after the crinkled set surface has been removed chining operation. removing the oxide concentrations the face the operation, all four sides the wire bar are form. Having started with superior cast- ing, the difference the wire more readily demonstrated ex- Scalping amining the drawn material. tensile strength and are not critical enough show any marked difference hard copper line wires produced from types wire Special tests, however, demonstrate the difference the wires fabricated from different castings. Oxygen-tree copper, due the very low oxygen content, shows resistance fracture when subjected right angle bends. made end-poured, and oxygen free wire bars offer greater stress due the more uniformly per- fect surface. The surface character- istics are found quite different when the wire subjected wrap The samples produced from the Draw block 4—Arrangement whereby wire scalped reversed die immediately after the drawing operation. 38—THE IRON AGE, September : 4 \\ | \ | 5—Specimens showing face skin peeled from rod means flat-faced re- versed die. One-half natural size standard commercial wire show surface cracks the (area severely. The uniform surface free from cracks obtained satisfactory bend test scalped copper shown Fig. The superior quality obtained the double scalping method demonstrated reference the companying photomicrographs. sec tion through typical surface perfection hot-rolled copper rod tion diameters. The correspond ing cross-section die scalped rod also shown Fig. marked freedom from all imperfections the edge the wire very noticeable. The method die scalping rods shown schematically Fig. The surface actually removed the same manner that the skin peeled from banana, and Fig. shows some specimens that were cut from cop per rod during the operation. The actual removal metal from the sur face the rod eliminates rolling de- fects and produces wire free from burrs, slivers, seams, laps, fins and dust. research ment, both the laboratory and the field, have shown that the magnet surface rods (double scalped) es- pecially suited the exacting require- ments copper windings formers, motors, generators and coils used the utility, air conditioning, transit and other industries served electric power. Blaw-Knox Offers New Dolomite Thrower improved dolomite throwing machine for making open- hearth banks has been developed Blaw-Knox Co. advan- tage the improved machine (illus- trated here) that operates under its own power. generator, driven either diesel gasoline engine, develops the electric power needed for the motor which drives the dolomite throwing mechanism, and also for the motor which propels the machine along the rails, thus enabling the machine well throwing the furnace banks. Thus crane service not neces- The hopper removable from the machine proper and fitted with trun- nions for engagement with metal ladle hooks the floor crane, that can used itself trans- port dolomite from storage open-hearth floor. Hopper capacities are made suit local conditions and are generally designed cient material make banks for three heats. Another improvement provision, that two classes material, e.g., raw and double burned dolomite, handled the same time the mere manipulation separate levers. THE IRON AGE, September Spectrographic Analysis REATMENT Data: Generally speaking, any reliable spectrographic method, possible for the operator control satisfactorily all variables except the photographic response the plate used record the spectrum. this non-uniformity ac- ceptable practice calibrates each plate correct for such fluctuations. cedure involves essentially the regis- tration series spectra differing effectively only relative intensity. Measurements this series evaluate plate response calibration curve depicting the manner which photo- graphic density increases function increasing relative incident inten- sity. Subsequent interpolation upon the calibration curve density measured for impurity line unknown spectrum serves give the corrected relative intensity the im- purity radiation the source, this intensity being measure percent- age content impurity the sample. This type plate calibration, un- less high-speed photometers are avail- able, rather time-consuming that each plate one must register and measure appropriate number calibrating spectra. Moreover, there the ever-present possibility that given plate not uniform over its entire surface that plate character- istics measured the calibrating spectra not hold for the area upon which unknown spectra are registered. the procedure described here each unknown spectrum acts, ef- fectively, its own plate calibrating agent. The essential advantages the method are that extraneous calibrating spectra need registered and that the plate area actually cali- brated more nearly the same that upon which the impurity line measured registered. The curve Fig. represents the manner which the density photographic deposit varies func- tion the logarithm the intensity the source, the time exposure 40—THE IRON AGE, September 1940 held constant. Following in- itial induction period (the toe), the density linear with respect log should noted here that with- this linearity range that the density changes most rapidly with log and, hence, possible, attempts should made work this region. With photometer the usual type the ex- posure usually controlled only seldom does density value pene- trate far into the linearity cause photometer readings dense lines are insensitive small changes. density. One advantage the vis- ual Gaertner densitometer that allows fairly accurate estimations even when density values are the range Fig. evident that the ratio b-d/a-c the four density the slope (gamma) the linear por- tion the D-log curve. Thus, the specific case the analy- sis for lead, the intensity the background radiation measured article gives de- tailed description the procedure adopted for the spectrographic pig lead. the first part, last week, the author cussed qualitative sensitivity limits, control excitation, prep- aration standards, and evaluation photographic density. Herein, conclu- near the line, the intensity neighboring line, and the intensity the background adjacent this reference line. as- sume that excitation conditions are controlled the extent that and are constant, the measured value the ratio dependent only the value (and, hence, only the concentration the un- known this ratio being inde- LEFT IG. 4—Typ- response curve. RIGHT IG. ver working curve. | | | | Log intensity Lead and Its Alloys sion, given method cor- rection which minimizes the necessity for plate calibra- tion and the plotting work- ing curves. Also, reproduci- bility demonstrated. Typi- cal analyses are given pig lead samples from different suppliers. The dure applicable the analysis antimonial lead and also calcium lead. pendent plate contrast and certain extent (depending the mag- nitude the linearity range) time exposure. The only prerequisite the method that all measured density values fall the straight-line portion the D-log curve. There has been found difficulty trolling exposure time satisfy this assumption the above treatment that the value plate gamma in- dependent the four wavelengths in- volved (Pb line and background, line and background). This strictly true but the differences gamma are slight that appre- ciable gain accuracy was observed when corrections for these were made. Plotting Working Curves Table are given densitometric data measured for the 3383 line and the reference 3221 line eight master standards. Background mated close possible the spec- tral line involved. The concentration values column were calculated the basis the amount add- the starting 6-9 lead just described. The working curve correlating the ratio b-d/a-c with the logarithm the concentration illustrated Reproducibility Data columns and the upper portion Table are given the MRGUDICH William Albert Noyes Laboratory Chemistry, University Illinois, Urbana, densitometric data obtained con- carrying the spectrum sample 222. Observed line densities, will noticed, are fairly constant and indicate that excitation and plate response were both reproducible. the case plates 16-1 and 16-2, even though the same excitation was used, wide variations exist plate response. The ratio b-d/a-c, however, remains fixed. This con- sidered strong evidence indicating the validity the correction proce- dure just outlined. data are given here only for the determination Pb, hut the same reproducibility was ob- served with Cu, and Cd. Accuracy Data The accuracy, correctness, the analytical results depends, obviously, upon the reliance that may placed upon the compositions the standard samples. was found because limited supply 6-9 lead, pre- pare these standards amounts cient for check chemical analyses. The Ag, and standards were checked duplicate synthesis and agreement was obtained. Most the master standards were spectrograph- ically analyzed independent lab- oratory, the only serious discrepancy reported 0.04 per cent con- tent the standard synthesized contain 0.05 per cent Bi. Finally, many lead samples spectrographically analyzed were subjected chemical analysis. difficulty has been en- countered checking and and amounts less than 0.075 per cent. the range 0.075 0.10 per cent spectrographic run slightly higher than chemical Bi. For example, series dif- ferent samples the spectrographic was 0.098, 0.105, 0.108, 0.084, 0.081 and 0.106 per cent, while correspond- ing chemical was 0.095, 0.095, 0.095, 0.082, 0.078, and 0.90 per cent. more concordant set samples THE IRON AGE, September “ect | | | | | } | | | | Log conc. Data Measured for Eight Master Standards b-d/a-c 1.85 1.73 1.35 0.66 0.44 0.26 0.12 0.0058 0.0057 0.0063 0.0056 0.0056 0.0060 0.0057 0.0063 0.0057 0.0060 0.0062 0.0063 0.0060 0.0054 0.0062 0.0059 0.0059 Average 0.0059 0.0059 0.0060 0.0060 0.00! Observed Scale Densities No. log 3383 3221 b-d a-c 0.0256 2.4082 44.4(18.2) 35.4 26.2 0.0064 3.8062 33.6(17.3) 41.7(17.1) 16.3 24.6 0.0016 3.2041 25.8(18.8) 44.8(17.9) 7.0 26.9 TABLE Data for Eighteen Different Plates Observed Scale Densities 3383 3221 b-d a-c b-d/a-c Plate No. (d) 33.3(19.1) 41.8(19.1) 14.2 22.7 0.626 32.8(19.1) 13.7 22.1 0.620 42.4(19.9) 14.8 22.5 0.658 40.8(18.2) 13.8 22.6 0.611 34.1(18.7) 23.4 0.658 38.3(16.5) 13.4 21.8 0.615 33.9(18.2) 43.0(18.4) 15.7 24.6 0.638 34.4(18.8) 42.8(18.9) 15.6 23.9 0.652 43.1(19.4) 15.6 23.7 0.658 33.2(18.4) 41.2(18.1) 14.8 32.9(19.2) 41.8(18.9) 13.7 22.9 0.598 34.4(19.3) 43.2(19.9) 15.1 23.3 0.648 43.2(19.4) 15.1 23.8 0.634 31.9(18.1) 13.8 21.9 0.630 Average deviation from mean 0.0002; Average deviation from mean (per cent) 3.9 23.8(11.0) 12.8 20.3 0.630 16-1 22.8(7.1) 10.0 0.637 49.6(20.0) 19.0 29.6 0.642 TABLE Data Supplier Sample No. 343 0.0050 0.0006 0.021 356 0.0052 0.0006 0.020 363 0.0048 0.0009 0.021 370 0.0053 0.0003 0.022 400 0.0052 0.021 423 0.0058 0.0003 0.024 439 0.0052 0.0003 0.022 473 0.0050 0.022 480 0.0052 0.0003 0.020 493 0.0052 0.0008 0.022 387 0.0008 0.073 388 0.0008 0.078 436 0.0005 0.0003 0.092 437 0.0007 0.0002 0.105 0.0009 0.0003 0.086 462 0.0008 0.0002 0.105 470 0.0005 0.0003 0.092 0.0005 0.0002 482 0.0008 0.069 483 0.0907 0.087 Typical 0.0031 0.0004 0.013 Typical 0.0011 0.0024 Typical 0.0004 0.0008 Typical 0.0003 0.0066 Typical 0.000! 0.090 Typical 0.0007 0.0003 Typical 0.0005 0.034 vvf very, very faint; faint; moderate; quantitative estimation. 42—THE IRON AGE, September 1940 0.001 strong, but still too faint for Seven Per Tin Sample Spectro- No. Deviation 4488 0.43 0.38 0.05 4489 0.42 0.44 0.02 4490 0.48 0.46 0.02 4491 0.37 0.35 0.02 4492 0.41 0.42 4493 0.38 0.35 0.03 4494 0.41 0.32 0.09 4495 0.44 0.50 0.06 4549 0.28 0.28 0.00 4550 0.31 0.25 0.06 4552 0.22 0.19 0.03 4553 0.29 0.25 0.04 4554 0.27 0.28 0.01 4598 0.26 0.26 0.00 4599 0.15 0.14 4600 0.26 0.27 0.28 0.28 0.00 4602 0.24 0.25 0.01 4603 0.22 0.22 0.00 4604 0.24 0.23 4605 0.17 0.14 0.03 4606 0.26 0.26 0.00 4607 0.27 0.26 4608 0.28 0.31 0.03 4609 0.18 0.22 0.04 4610 0.19 0.20 0.01 Three and One-half Per Cent Antimonial Lead Tin Sample Spectro- No. Deviation 5046 0.37 0.38 5047 0.24 0.26 0.02 5048 0.27 0.24 0.03 5050 0.26 0.26 0.00 0.28 0.27 0.01 0.14 0.14 0.00 5092 0.21 0.24 0.03 could have been selected, but the one given illustrates fairly well the gen- eral magnitude the discrepancy. Self-explanatory analytical data are given Table ITT. Speed Analysis The speed spectrographic meth- ods too well recognized require amplification here. one occasion, was possible, although particular efforts have been made develop rapid method, analyze one day pig lead samples quantitatively for Cu, Bi, and and qualitatively for As, Sb, Sn, Ni, and Fe. Antimonial Lead Analysis The data Table illustrate pre- liminary comparisons chemical and spectrographic analyses both and per cent antimonial lead. The spectrographic data were obtained us- ing experimental conditions identical with those adopted for the pig lead program, except that the exposure time was reduced min. Chem- ically analyzed samples rather than synthetically prepared standards were Chen Antir | | | } ts ) —--- = - : : Chemical and Spectrographic Analyses Antimonial Lea Chemical Spectrographic Deviation 0.047 0.048 0.014 0.014 0.000 0.018 0.023 0.005 0.021 0.023 0.002 0.100 0.099 0.045 0.049 0.004 0.052 0.072 0.070 0.002 0.022 0.024 0.002 0.026 0.029 0.003 0.010 0.010 0.000 0.040 0.035 0.005 0.036 0.031 0.005 used plotting the antimonial lead working curves. Only relatively small number antimonial leads have been felt that both accuracy and pre- cision will considerably increased the future, since each sample sub- jected both chemical and spectro- graphic analysis will add the reli- ability the working curve. Calcium Lead Analysis Preliminary investigations out with the cooperation Dr. Homan, the Commonwealth Edison Co., have indicated strongly that ex- citation conditions adopted for the pig lead program are quite applicable hoth for the analysis the calcium and the trace impurities this alloy. Acknowledgment The author finds express adequately his appreciation for the help the individuals and concerns cooperating this project. especially indebted Professors Wilson, the Electric Auto-Lite Co. Wood and Fitch, the Prest- O-Lite Storage Battery Corp., Lawton, the Battery Corp. and Professor Pierce, the University Chicago. The research Electric Auto-Lite Co., Toledo, cooperative fellowship maintained the University Pipes and Fittings Carbon and Graphite high resistance corro- sion offered pipe and fittings made carbon, graphite Karbate after severe tests, has aroused considerable interest this compar- atively new product, particularly the stainless steel field. The materials, made National Carbon Co., Inc., Cleveland, have high thermal conductivity and are said highly resistant thermal shock. pickling tanks they have been installed inlet and outlet pipes and for submerged gas heaters. Carbon and graphite resist corro- sive action all acids, alkalies and salt solutions except those highly oxidizing nature. For example, hy- drofluoric acid has effect car- bon. Graphite more resistant idation which permits its use under higher temperatures. Carbon and graphite products usually manufactured, are slightly po- rous and thus not entirely impervious the seepage liquids and gases under high pressure. The Karbate materials which National Carbon Co. has developed are how- ever. Karbate No. carbon-base material and Karbate No. graphite-base product. The latter has better heat conducting properties, and particularly applicable heat ex- changing operations. DAPTED many applications where corrosion problem, pipe and fittings carbon, graphite such shown here are proving satisfactory under severe service tests. Karbate light weight, has low coefficient thermal expansion, good electrical conductivity, high resistance thermal shock, and said pos- sess greater mechanical strength than corresponding carbon graphite products. attacked only highly oxidizing agents. Its use confined temperatures 338 deg. F., but the surface may ex- posed higher temperatures means are provided carry off heat from the opposite surface fast enough keep the body the material below the critical temperature. sulphuric acid pickling solutions for steel, both graphite and Karbate No. pipe are claimed have shown evidence acid attack after six months’ immersion. Graphite rather than Karbate pipe recommended for nitric acid solu- tions, where the seepage problem the lesser evil. nitric and pick- ling solution for stainless steel, stated that one plant has used graph- ite pipe for several months without apparent acid attack the pipe. The Saunders type valve with Karbate hody available, that complete systems may assembled. Both threaded type and flanged type fittings are manufactured. threaded type fittings thread uniform diameter used. THE IRON AGE, September 1940—43 | ~ a ‘ . = | 4 . | | | | rated with the same degree probability. DEFECTS Shrinks (A) voids, draws sponginess present irregularly shaped cavities, interiors which are lined with dendritic crystals. Defects generally found near center heavy sections near change section thickness. section size. Lack fillets. (B) Common sinks depressions appearing Isolated heavy cope side heavy flat castings. Open sections. closed pipes appearing cope sides heavy bosses, lugs columns, with longest side vertical section. Cracks (A) Due internal stresses set casting while cooling. different section thicknesses. pattern. Common long thin plates, cylinder heads, etc. Hard Excessive hardness, making machin- ing difficult. Hard Small hard areas visible naked eye and large enough interfere with machining operations. surfaces. Fracture shows coarse crystalline structure. ings not match parting line. Core core adds thick- ness one side wall cored area and re- moves like amount from opposite walls. Also section casting formed core which improperly located. breaking off and moving toward upper surface casting. 10. Veriation Wall untrue specifications. Casting section embedded wall casting. 13. Cold Shut—Metal fails join properly. casual examination appear cracks. | Incompletely filled mold cavity. Also appears smoothly rounded hole through wall casting. Especially noticeable cor- ners and projections. 16. Slag Inclusions—Appear surface cast- ing vicinity gates along line metal flow. Inclusions have vitrified appearance. removal inclusions leaves dull black cavity. ABLE lists types defects found gray iron cast- ings and the causes according degree probability. Most probable cause indicated second most probable (2), etc. some instances two causes may Too abrupt change Casting poorly de- signed, promoting | wide variations in cooling rates the FLASKS Low sprue head due shallow cope flask. Flask bars too close mold cavity. Worn pins and bushings. sprue head. Low head. Warped flasks. Flask too small. joint flask. prints. PATTERN EQUIPMENT Improperly design- pattern. Bad design. Too abrupt change casting thick- ness. Cope and drag pattern not matched. MOLD-SETTING AND CLAMPING Bad clamping, loose pins and bushings. Rolling weighted molds Insufficient core (es) Insufficient Core prints. core boxes. Im- properly mounted pattern. (1) Worn pattern core boxes. Bearing surfaces | worn or not prop- erly cleaned. gravity conv’rs. | clamped off. Mold improperly clamped bedded Improper gating GATING Improper Lack ample risers. and lack ample risers. Improperly Improper gating. Improper Improper gating. incorrectl y arranged rela- tion thin sections. Gates too Sprue too near side, runner too near joint flask. lo Size sprues and pouring basin not Gates nozzling effect. 44—THE IRON AGE, September 1940 . mol |= chi 11. Variations Length and Width—Length and width casting varies from pattern dimensions. | | | 1 | | | MOLDING MOLDING SAND CORES METAL MELTING POURING SHAKE OUT OTHER e Position for sec- ature too high or tion thickness. low for method gating and risering. 1 3 Molding sand too car- Pouring temper- high colloidal bon too high. ature too high clay bond. for method gating and com- position rammed Hot strength too Hard cores. Incorrect metal Incorrect shake Improperly heat mold. high. composition. out time. treated. Rate use Foreign material chills. sand. Shift match plate during roll over. Insufficient chap- lets. Cores not set correctly. Soft ramming around core print. Insufficient chap- lets. @) Excessive pattern rapping. Cores in- correctly set. Un- mold ram- ming. Excessive pattern rapping. Hard ramming. Moisture too high. Lack venting. Permeability too low. Too much sea coal. Moisture too high. too low. Too much sea coal. Soft ramming be- tween mold cavity, sprue runner and flask edge. Core mold vents not Properly pro- tected. | _— Improperly conditioned. rods wires exposed. efects Carbon and sili- con too low. Car- bide stabilizing elements too high. Carbon and sili- Bad melting con toolow. hot metal trans- bide stabilizing fer. elements too high. Carbon con too high. Car- bide stabilizing elements too low. 1 jigged, assembled. 3 gaged forced cores. Bad bonding. Over- baking. Rough handling. Cores not true core boxes. Cores not properly jigged. assembled. 3 4 | gaged Variations composition metal during the heat. Bad melting hot transfer practice. Fluidity too low. Bad melting hot transfer practice. Fluidity too low. melting hot transfer practice. Metal melted too cold free itself entrapped Metal contains entrapped Dross from lad addition, slag. Spout etc., not properly ladle lining skimmed. low refractori- ness. McFERRIN, Foundry Metallurgist Cadillac Motor Car Division, General Motors Sales Corp. Detroit Incorrect shake out time. (3) heat treated. Casting too hot. Cold iron. Inter- rupted pouring. Pouring temper- ature too low for method _ing. Interrupted pouring. Pouring temper- ature too low. Pouring temper- ature too low. Interrupted slow pouring. Clamps weights taken off Cast- too soon. ing too hot. Bad pouring and skimming. 3 THE IRON AGE, September heating cool- ing too rapid for design. Rough hand- ling. not properly sup- ported when Improperly heat treated. Improperly heat treated. ne. | 3 | 2 2 | 2 we ~ | cares DEFECTS CAUSES 17. Sand irregular shape and size, inner surface of which shows imprint granular material. around core prints. mold dropping into mold cavity. 20. Rat due portion mold face sticking pocket pattern. placement sand molten metal. 22. Cuts and Washes—Rough lumps metal rounded corners which should sharp. Along line flow will found granular depressions holes. 23. Metal Penetration—Sand pockets in- ternal cores difficult remove due penetra- tion metal into sand, forming fused mass metal and sand. Causes Gray Iron PATTERN MOLD-SETTING EQUIPMENT AND CLAMPING GATING DESIGN Worn pattern Excessive weight- core box. Core ing mold. Im- print too small for proper clamping core. Mismatched bedding cope and drag mold. pattern. Q@) ® bars Rough handling. flas flasks. (3) Not enough draft pattern. Pat- tern loose molding machine. Molding machine draws too fast. Mold not clamped im- properly bedded. Flasks not rigid. Additional bars needed. Improper gating. 24. Burning into Sand— Parts outer casting have rough sandy appearance. 25. Burning Core—Rough, sandy appear- ance inner part casting with some sand embedded the surface. Also appears fins penetrating into core and holding grains core sand. thin walled casting. Usually po