The Iron Age 1940-09-26: Vol 146 Iss 13

SEPTEMBER 26, 1940 VOL. 146 NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor News Editor Technical Editor Machine Associate Associate Editor Editor Editor Art Editor Editor Emeritus Washiagton Editors MOFFETT JAMES ELLIS Resident District Editors CAMPBELL HERMAN KLEIN 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, Editorial The Girl Left Behind Him Technical Articles Adhesion Nickel Deposits Handling Scrap Metal Efficiently Milling Machine Manufacture Quality Finishes for Metal Products Short Cycle Annealing What's New ..... Pendulum Hardness Testing Machine Feature Reports the Assembly Line Washington News News and Market Reports News ofIndustry Machine Tool Activity Personals Non-Ferrous Metal Market Obituaries Scrap Market and Prices Metal Working Activity Construction Steel Comparison Prices Iron and Steel Prices Summary the Week Ferroalloys, Pig Iron Prices The Industrial Pace Warehouse Prices District Market Reports Sales Possibilities Fatigue Cracks Free Industrial Literature Products Advertised Index Advertisers Copyright, 1940, Chilton Company DIX, Manager Reader Service Owned and Published CHILTON COMPANY (Incorporated) Advertising Staff Publication Editorial and Office Executive Offices Robert 62! Union Cleveiand Chestnut and Sts. East 42nd St., Herrnan, Chilton Bldg., Philadelphia Philadelphia, Pa. New York, Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Warren, Box 81, Hartford, Conn. Don F. Harner, 1595 Pacific Avenue, Long Beach, Cal. Emerson Findley. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President VAN DEVENTER, Vice-President Member, Audit Bureau Circulations Member, Associated Business Papers BAUR, Vice-President Indexed the Industrial Arts Index. WILLIAM BARBER, Treasurer lished every Thursday. Subscription Price JOHN BLAIR MOFFETT, Secretary United States and Possessions, Mexico, Cuba Canada, $8.50; Foreign, $12.09 yeor. Single copy, cents. JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE 38-B 124 after hours, any the ten Ryerson steel plants, almost any night the year! The Ryerson night shift putting the finishing touches today’s orders; loading out the fleet big, red Ryerson trucks for tomorrow’s deliveries. Immediate Steel Ryerson tradition. The entire Ryerson organization geared handle quickly the steel requirements, simple involved, thou- sands customers the country over. Special tele- phone order desks, hourly mail pick-ups the post office, telegraph and teletype lines right into our offices—all help speed delivery, even before the order reaches us. Night loading the decks” for tomorrow’s new crop orders the regular course business. Every order RUSH Ryerson—most are shipped the day received. Ryerson Steel Service fast and sure; Ryerson Cer- tified quality your assurance uniformity and exactness. Make the Ryerson Stock List your unfail- ing source for all steel requirements. you the latest Stock List send one gladly. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Phila- delphia, Jersey City. Loading f | y < by, The Girl Left Behind Him IFTY-TWO times year this page primarily addressed readers. There are quite numper advertisers among them, course, because reach great many executives whose firms advertise their products and who have considerable say determining promotion and publicity policies. This being leap year, have issues The Iron Age instead the usual 52, and going take advantage the extra page talk purely about advertising. For with all this munitions work going on, the question sometimes asked: “Why and what should advertise cannot fill Now, what does the word mean? You would probably get hundred different answers from hundred different people. Perhaps have observed, the function advertising get people want what you make and keep them wanting it. And the latter especially important when you cannot satisfy your normal customers these abnormal times. reminds the story the young soldier who was called war and was obliged leave his sweetheart for indefinite time. You remember, Girl Left Behind The boy who went war was very much love with the girl left behind him. And she with him. But she was beautiful girl who had many admirers. And our young friend was too wise believe the old proverb: makes the heart grow fonder.” knew that the modern version was that his absence would make the other guys grow fonder, and the girl, perhaps, less fond. ESTABLISHED Our hero resolved that after all the effort and time that had 1855 spent winning his affections and his place No. man, would not let his rivals win default through his absence. No, indeed, would see that she was reminded him often and the good times that they had had together and the better times that they could have after the war was over. the boy who left the girl behind inaugurated and carried out campaign promotion keep from becoming the forgotten man. Some- times when there much activity aside from drills, was hard put find interesting things talk about, but could always tell her how much missed her, how much loved her and how much wanted with her again. And boys, believe that letter that she got from him every week two kept her thinking about him and kept her from thinking too much about the temporary beaux who took her out the meantime. Perhaps, you will find moral this with respect advertising under present-day conditions. For certainly, your biggest promotion job today, when you are called war work, make people keep wanting what you make, whether not they can get it. And keep them wanting until you are ready give them. It's hard forget some one that made remember! aa Bas 2 q SEPT. 26, 1940 it | | i} Manufacturers machine tools long ago adopted the sound selling practice proving their customers that machine tools new designs make better prod- ucts lower costs. The reward for these alert and untiring sales efforts has been vastly greater volume machine tool orders. Fabricators structurak steel can take that page from the machine tool industry’s “success book.” Never before have fabricators had many good arguments, including low interest rates, with which get new business. Thousands manufacturing plants are doing business buildings which are handicap manufacturing. Today the industrial architect, con- tractor and fabricator far more than simply build. They can make structures that are really “tools” for manufacturing, tools that will give the manufacturer Opportunity for Fabricators Increase Sales! valuable advantage lowered costs and higher profits. Yet, thousands manufacturers are not fully aware these facts. Many are struggling along outmoded structures that are definite business handicap. Fabri- cators who will step out and sell structures which better products can made lower cost will open new realm opportunity. Inland engineers are espe- cially equipped many years practical experience give fabricators valuable engineering assistance. free for the asking. INLAND STEEL CO. Dearborn Street, Chicago Sales Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas City, Cincinnati STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS | fe} Adhesion Nickel Deposits ROEHL Research Laboratory, International Nickel Co., Bayonne, Ollard adhesion test used evaluate the efficiency various etch- ing methods the preparation several basis metals prior nickel plating. Also study the Ollard test procedure has shown that suit- able choice exact dimensions the test piece and apparatus, adhesion values can obtained which represent closer approach tensile separa- tion deposit and basis metal than that obtained the original Ollard test, both from practical and theoretical viewpoints. Satisfactory etching methods for preparing the following basis metals are demonstrated herein: high and low-carbon steels, cast iron, wrought iron, com- posite surfaces nickel and steel, and nickel itself. Satisfactory etching methods also are given for Ni-Mo steel and Ni-Mo cast iron. With steel base, adhesion greater than the tensile strength the electrodeposit was observed, and with cast iron the break takes place the basis metal. Perfect adhesion nickel nickel exemplified continua- tion the basis metal structure the deposit itself. the various tests which have been devised determine quantitatively the degree ad- metals, the method due and applied the most satisfactory. The present paper de- scribes refinement Ollard’s test more closely defining the dimen- sions the test piece that when the 1Ollard: Deposited Nick- Base Metal,” Trans. Faraday Soc. 21, (1925). “The Adhesion Elec- trodeposited Coatings Steel,” Trans. Electrochem. Soc. 64, (1933). deposit and basis metal are separated, the break occurs more nearly tensile method study has been made vari- ous basis metal cleaning treatments, order evaluate their efficiency and provide treatments which will en- sure high adhesion nickel deposits, both hard and soft, number basis metals. The basis metals studied are: high and low-carbon steels, cast and wrought iron, composite nickel and steel surfaces, nickel itself, copper, Ni-Mo steel and Ni-Mo cast iron. The problem the adhesion de- posit basis metal one primary importance all types plating, but the field heavy nickel deposits for the building worn mis- machined parts and for the protection parts against combined wear and corrosion, good adhesion requisite. The deposits are often ground machined size, may used bearing surfaces, and thus subjected high stress. Since these parts rarely have their primary ob- ject the production attractively appearing surface, cleaning methods may employed which would out the question for decorative work. The hardness nickel electrodeposits can varied, depending upon the plating conditions, from 160 500 Vickers, and thus provide wide scope for various engineering purposes. The Ollard Test Fig. shows the various steps the Ollard test method. machined test piece 1.00-in. diameter 1.50- in. long fitted with connecting wire; the whole specimen stopped off with Halowax and the wax then removed from portion the surface the method desired study and approximately 0.10 in. thick formed the exposed end. The wax then removed and the THE IRON AGE, September 26, ce ° = | ° ° | | | | - | \ i] | ; Bi steps the Ollard test method. About actual size. oO ip) Anode current efficiency Amps. per solutions. 2 4 Ye ' 5—Cast iron with poorly distributed carbon, direction parallel deposit. Unetched. 100 diameters. IRON AGE, September 26, 1940 Nickel Interface 2—Cross-section Ollard test specimen. 4—Cast iron with well distributed carbon, direction parallel deposit. Unetched. 100 diameters. + « 8 6—Wrought iron direction parallel de- posit. Unetched. 100 diameters. | | SS | | | ‘ | @ . . . 4 ‘ + 7 j oF * » » piece machined give total length 1.51 in. from the unplated end the under side the nickel that is, 0.01 in. nickel machined off that nickel will remain the cylindrical surface the test piece itself and the interface between nickel and basis metal will well below the shoulder the finished specimen. the same time hole in. about in. depth drilled through the nickel and basis metal, indicated The test piece then supported the die and load ap- machine. indicates the appearance the test piece after the nickel ring has been forced off. From the value the load and the area contact tween deposits and basis metal, the adhesion terms Ib. per sq. can calculated. specimen just prior breaking the tensile machine. Study Adhesion most important factor obtain ing good adhesion adequate cleaning preparation the surface the hasis metal. The surface chemically clean and for maximum Where the values are the same order magnitude the tensile strength the basis metal, the weak polishing must removed etching. order study the efficiency various cleaning procedures, number samples steel, cast and wrought iron were prepared and tested for ad- Ollard’s method. The pro cedure shown Table was followed. The first action the etch laver and expose the crystal structure, which the work goes passive and gasses. During the first stage the treatment the anode efficiency the dissolving iron quite low can seen Fig. taken from the work where the anode current density plotted against the anode efficiency for iron solutions 22° Be.) Some gassing will thus occur during this period, and film left the surface. neces- sary remove this film (it probably not removed method Table order secure good adhesion and this accomplished during the second stage the treatment when vigorous gassing occurs—at point “The Repair Worn Com- ponents Met. Ind, (L) 24, 521 (1924). ‘Salauze: “Traite Galvanoplastie,” 240 (1935). TABLE Procedure Followed Prepare Specimens for Adhesion Test Plating Bath: 330 gm. per liter gm. per liter gm. per liter 130 deg. F., 2.0 amp. per sq. ft. Deposit hardness 160 Vickers Test Piece Dimensions: Deposit thickness 0.070 0.10 in. 1.030 in. hole diameter die Duplicate runs all cases Preliminary Cleaning Treatment: Pumice scrub and cold water rinse. Cathodic alkaline treatment for min. 100 amp. per sq. ft., 140 deg. F., solution composed gm. per liter NaOH, 1.06 gm. per liter Pumice scrub and cold water rinse. Cathodic alkaline treatment for min. Cold water rinse. This procedure was then followed the various etching treatments indicated Table then cold water rinse, after which they were placed the plating bath with the electrical connections made. TABLE Etching Treatments and Adhesion Values, Using the Original Ollard Test. Steel Basis Metal. Ollard Test Values (Lb. Per Sq. Etching Treatment Drill Rod Mild Steel (0.97 (0.20 C.) immersion per cent (by weight) 6,300 5,200 140 deg. F., min. (2) Anodic, per cent (by weight), amp. 16,000 22,500 per sq. ft., room temperature, min. Increase current density 200 amp. per sq. ft., for min. Cathodic for sec. (3) Anodic, per cent (by weight), 200 amp. 7,500 per sq. ft., room temperature, min. Cathodic for sec. (4) Anodic, per cent (by weight), 200 amp. per sq. ft., room temperature, min. 16,000 13,000 min. 18,000 15,500 min. 18,000 (5) Anodic, per cent H.SO, (by weight), 100 amp. adhesion per sq. ft., room temperature, sec. (6) Method Anodic, per cent 18,000 8,500 (by weight), 100 amp. per sq. ft., room tem- perature, for sec., after oxygen first evolved TABLE Etching Treatments and Adhesion Values, Using the Original Ollard Test. Cast and Wrought Iron. Ollard Test Basis Metal Etching Treatment Values, Lb. Per In. Cast iron with well-distributed amp. per sq. ft. Removed carbon (Fig. soon gassing started min.) 985 (2) 100 amp. per sq. ft. Allowed gas for min. 20,000 (3) amp. per sq. ft. time min.—gassed for min. 20,000 (4) 200 amp. per sq. ft. min. 4,160 (5) 200 amp. per sq. ft. min. 16,900 (6) 400 amp. per sq. ft. min. 13,000 400 amp. per sq. ft. min. 12,500 Cast iron with poorly distributed amp. per sq. ft. min. 15,000 carbon Wrought iron with slag inclusions 100 amp. per sq. ft. min. 13,800 (Fig. THE IRON AGE, September 26, ihe. J | | ve i | | > | | age | | | | ! Pe \ | ? | | | _ during this stage the film lifted, al- most one piece, leaving bright surface the case mild steel and generally rather darker one for high carbon steel. The cleaning treatment all the following cases consisted, 8—Cast iron. Extent with No. treatment. 100 diameters. LEFT 7—Cast iron specimen after break. Twice ac- same preliminary procedure per cent (by weight) room temperature. Results are given Table shows the specimen obtained under treatment No. can seen tual size. that the break occurred entirely the cast Fig. shows the extent which etching the basis metal oc- curred under treatment Ed. Note: Next week the author concludes this in- teresting investigation. Handling Scrap Metal Efficiently problem handling waste metal materials resulting from processing parts the ma- chine shop, one that often proves real headache many plant. How one manufacturing concern has solved this problem interesting. This particular company has lot scrap tin contend Two things are done. they put through 20—THE IRON AGE, September 26, 1940 heating furnace where all the tin reclaimed, and second the scrap put through shredder and then pressed into bales about 18x15 in. bale pressed under 300 tons pressure and weighs about 200 Ib. The bales scrap then back the steel mills. handling this material, one the most serious problems was that weighing the bales. the operators are paid tonnage basis, was im- portant that each bale weighed quickly and accurately. dial with printer and operated means electric eye finally operated the satisfaction both labor and man- agement. the accompanying picture shows, graduated 500 Ib. and without tare capacity beams, was installed. equipped with Printomatic with time clock, one bank letters, one bank numbers and one bank spe- cial symbols. The printer attachment equipped with double roll tape. section roller conveyor mounted the scale while endless belt ft. long and in. wide passes over the scale platform neath the scale box. The belt speed about ft. per min. the bale comes from the press and drops onto the moving belt, carried across the scale platform. Then the instant the bale passes over cen- ter the platform, intercepts This automatically trips the printing mechanism and prints the weight. The Printomatic set weigh bale scrap metal about every sec. | a ° ° ° ROBERT BINGHAM ° ° eight months unrelent- ing effort, the Kearney Trecker Corp., Milwaukee, World’s exclusive manufac- turer milling machines, has realized goal, which, when visualized De- cember, 1939, seemed distant the moon, and nearly difficult attain. that period, the company has in- creased production 140 per cent, area per cent. Furthermore, the new plant which made possible this tremendous boost output is, far known, the only plant the world where machine tools are manufactured and assembled production line basis similar that employed the automobile industry, differing mainly that moving lines conveyors are used. One the first receive volume orders for identical machines, T., was able revamp its old plant blend with the new production line sys- tem because this unprecedented de- mand for milling from abroad and home. The great problem that faced the management its decision con- vert its plant was how achieve production line sacrificing the same time the flexi- bility manufacture that called for line that includes over 140 varie- ties bed and knee type milling machines, all differing principal characteristics. The objective was, and is, manu- facture not milling components such columns, knees, tables, pulley brackets, and on, and then assemble these components into the size and type machine specified the customer. The first task, there- Milling Machine —in the modern manner. Kearney Trecker institutes production line basis and less than year increases production 140 per cent, personnel per cent and area per cent. fore, increase the production these components, which December, 1939, were being made the rate about 2500 monthly. goal 6000 components month was set up, and August, 1940, this figure was reached—this after expenditure some $2,000,000, the hiring nearly 1300 persons and the purchase 227 machine tools and other necessary equipment. Yet, with all this high production planning, the still flexibility. Unlike lines where each machine man has set fixed quota and job for which responsibility assigned, each department has certain ma- chines which are capable producing excess the demands placed upon them. When their work finished they are then available case bottlenecks develop elsewhere the plant similar machines. some plants, bottleneck slows down and sometimes stops work throughout can usually remedied transfer- located elsewhere, sometimes entirely unrelated department. Also, when demand for one type milling machine far exceeds that for another, and the consequent need for certain components greater than for others, work can transferred from those machines that are crowded those whose regular work com- ponents not demand the moment. The number components varies much per cent with the different Although the theory the new plant calls for routing all components through the stock room the assem- bly line, actual practice today many components directly from manufac- turing into assembly. Under less active production conditions, when manufac- turing schedules cannot made THE IRON AGE, September 26, \ f tr € | | | \ i ERS } \ | | \ | SCRAPING WASHER ATTACHMENT KNEE INTERNAL THREAD MILLER GRINDERS SUB ROUTE LAB DRILLING FIRST LEAD CREW DEPT. ARBOR AND HIS flow chart the basis which ranged its conform. Notice the double vertical the center the left half the chart. The the point between the been achieved obvious after study this lay- out. 22—THE IRON AGE, September 26, PAINT HOP FITTING ROOM DEPT. POLI: s 4 0 DEPT. SHIPPING DEPT. PAINTING STOCK ROOM DEPT. DEPT. LUMBER SHED ROOM HEAT ELECTRIC DEPT. LOCKERS 4 MILLING SUB ROUTE WATER ANK MACHINING INSPECTION DEPARTMENT THE IRON AGE, September 26, 1940—23 4 | AGE | months advance today, the base components which into every mill- ing machine, regardless type size, would made according pre- arranged inventory plan. From that point the various components which make one machine different from another would ordered from stock according consumer requirements. time are milling machines assem- bled for stock. Only the components are stocked, and they only cer- tain point. broken for 70,000 sq. ft. addition the old plant which comprised 220,000 sq. ft. Employees that time num- bered 1506 and production com- ponets was approximately 2500 month. mere days thereafter the first machine tool was installed the new structure and placed operation. cision gear line which out 480,000 gears 2100 different types annually started up. Even before this expansion had been completed, became apparent that more room would needed, and further addition 20,000 sq. ft. was Much the credit for bringing the new plant successful completion rapidly was due the cooperation other machine tool builders. Since 24—THE IRON AGE, September 26, 1940 view the special T-slot milling machine designed and built for its own use. The tanks left are part the chip exhaust system. Insert upper left— these three gashing cutters precede the T-slot cutters shown insert the right. Separating the two are three exhaust inlets which cap- ture the gashing chips before the T-slotters enter the cut. The ex- tremely close fit the T-slot cut- ters necessitates the elimination all chips. Also shown the insert upper right are the two tiny ex- haust pipes that suck the chips away from the side T-slot cutter. most the 200 new machines ordered were individually motor driven, they were placed production soon they reached the. shop floor. Nearly all the 450 machine tools the old plant were moved and re- arranged coincide with the produc- tion plan set for the new building. When all this moving was completed, the old and new plants been blended together perfectly, into in- tegrated unit, which entirely reversed the former conception manufacturing. The old plant had been arranged departments types machine tools. mill the front face and front edge the knee casting required transpor- tation the knee the milling ma- chine department. When holes were drilled, bored and reamed, the knee would travel either the radial drill tion, and through the various operations, Arrangement New Plant The new setup includes one partment wherever possible the machining equipment incident manufacture individual piece part. Thus the knee department today the locale more than separate operations the knee casting which starts through just comes from the cleaning and priming department. Included the knee department are two types planers, three types milling machines, radial drills, and three boring bars. For the small parts, some machine tool still exist, such turret lathes, grinders, drilling, thread millers, ete. Over 200 Machines Ordered that this system could properly put into execution, more than 200 machine tools were ordered, thus ex- the old saying that the ma- chine tool industry one its own customers. Included were lathes various types, boring bars and boring mills, drills, radial and sensitive, automatics, machines for gear cutting and testing, varied milling machines, types grinders, heat treating furnace, complete spray hooths, shot blast room, cranes, electric hoists and electric trucks. With the equipment ordered, the next big problem was personnel operate the machines, and staff the plant generally. pre- liminary figure, increase about 600 men, roughly per cent over the 1939, total was contem- plated. When the 600 workers had been hired, the doors the ment department remained open and today they open, though nearly 1300 persons have been taken on, nearly many were employed all the old plant. waukee, busy times impossible hire 1300 skilled workers. Yet had have machine operators and erectors for the assembly lines, the management took matters into its ORTION the main assembly section for knee-type machines. own hands and solved the enigma novel and expensive, but effective manner. Modern machine tools, the executives reasoned, are either fully semi-automatic. little practice any dependable man with common sense and the ability learn should able acquire skill, they several weeks, therefore, while new equipment was being ordered, 579 alongside veteran employees watching and learning the operations that they themselves later. these, 185 were classified special learners and 394 helpers. Many the latter were hired for the departments, Trained Own Skilled Labor Thus was that when the machines finally arrived, the chinists definitely advanced now were able feel thoroughly ease their jobs only few hours’ time, and begin productive effort almost immediately. order sure that quality was this large increase new workers, the inspection staff was expanded materially. Today, boasts general shop inspectors, gear inspectors and preliminary and final testers. Inspection Department Enlarged Individual inspection sheets for each the thousands parts milling machine are file. these sheets listed the inspection operations that are carried out for each part piece. After each operation manufacturing route sheet, the first completed piece each lot spected, and certain pieces thereafter until per cent the lot has been checked. example the muiti- plicity inspecting operations, the route sheet for the knee casting car- ries machining operations, and one- third the knees each lot must inspected after each these oper- ations. The final tests which all machines are subjected are themselves marvels precision. test card for ver- tical milling machine includes exactly tests, including actual cutting test seven feeds 190 210 brinell test block. Horizontal milling machines are run through tests in- cluding the cutting test. Allowable error does not exceed THE IRON AGE, September 26, 1940—25 0.001 0.0005 in. the various alinement tests made both the hori- zontal and vertical types. The old bugaboo shortage skilled labor was utterly disregarded T., which, spite the fact otherwise was complaining the sit- uation, went out and made its own skilled men. Other plants, course, have had plans for training unskilled men, but the sight 579 men, nearly half all those hired, standing along- side machines and experienced work- ers, watching, and learning, was one excite admiration and comment. Two Plants Like One Today stranger the plant would think the entire structure had been built the same time, judged entirely the straight line produc- tion parts, flow material, and assembly. Only inspecting the roof girders, and flooring, and compar- ing the types construction, can one differentiate between the old and the new. The flow chart, reproduced here, provided the basis which the two plant were welded into one whole unit concerns manufacturing. Basically milling machine consists column, either vertical hori- zontal, knee, saddle and table. Consequently the rearrange- ment concentrates into one department best can, the various operations each these component parts. From the time casting comes into the storage yard across the street from the main buildings, its progress carefully and accurately charted and checked heat steel route through the various roughing and fin- ishing mills. T.’s castings, all which are poured outside foun- dries, are first sent the cleaning and priming department for shot blasting and chipping. The shot blast, with about nozzle pressure, has re- duced the amount time per casting this department about half, ac- cording shop officials. another section this building many the small parts are started their way through the automatic turret lathes, which are new. Production this department has increased nearly 100 per cent since the new equipment was installed and shifts increased. this building also are stored gear blanks, bar stock and spindle forgings. From here small parts and the large castings pursue different courses until once more they meet _assembly line. The columns, knees saddles start out together but branch off along the route individual departments. 26—THE IRON AGE, September 26, 1940 typical column undergoes separate operations, which are performed the column department proper, after entering the main building. Seven different types machine tools are used the columns, but many these perform more than one opera- tion. general these include medium and large planers, boring bars, special duplex and multiple bars, hori- zontal knee type milling machines, and radial drills. give another example, the small spindle gear, which follows path its own the main building, requires operations, which are machin- ing. the 19, are performed the gear department proper, and the other four are divided between two other departments. Formerly, these machining operations were spread over maximum number any one depart- ment. the columns follow their course, they into the fitting room where various parts are added, and from there into the paint booths, after which the scraping department gets the castings. degreasing wash, and the casting ready enter the main production flow line where beth knee type and bed type assembled. right angles the machine assembly line are assembly depart- ments for knees, tables, saddles and dividing héads, all essential compo- nents. Small parts are received from the stock room these assembly points and the components are pletely assembled units before final assembly the column. Knee assem- bly, for example, consists delivering the knee assembly department, the knee casting, finish machined. The casting swung onto metal stand, the lower shelf which contains all the parts assembled into the unit. The parts turn assembled adjacent aisle. One man assembles the entire knee unit, nearly being required for this wholly hand operation. Finish assembly soon completed and after severe check the test room, details which have been dis- cussed, and final painting, the ma- chines are ready for shipment. Castings and parts throughout the production and assembly lines are moved traveling cranes and hoists, electric trucks and gas tractors. Small parts are handled quantities 2-wheel hand trucks and hand lift trucks. moving assembly lines conveyor belts are employed this plant. One T.’s strongest talking points its precision gear department. About 40,000 gears are produced month this plant for its own use, and the course year approxi- mately 2100 different types are made. The new addition called for the in- stallation new gear cutting ma- chines the gear line, including gen- erators, shapers, hobbers, lappers, All these were added the equipment acquired $200,000 gear program completed June last year. Gears are now made almost entirely the one department, number transfers around the shop were necessary. The cutting each gear has thereby been speeded sub- stantially. 40,000 Precision Gears Month unusually complete gear testing laboratory complements the production line. conditioned, sound proofed and specially illuminated, the gear lab represents the ultimate gear con- trol. For each the 800 900 gears made for the many models Mil- waukee milling machines, the gear de- partment maintains setup cards. These cards tell the operator the exact oper- ation, arbor cutter tool, feed, speed, passes, and machine number used for the particular gear ordered. special gear gasher outstanding the gear cutting production line. Designed company engineers, consists standard milling machine plus special head and hydraulic clamping and indexing fix- tures. The teeth the 12-in. diameter cutter are spaced that overheating uncommon even stock. Spindle speeds range from 30-in, diameter fly- wheel carried the spindle and eliminates vibrations from the cutter. The performance the gasher worth close attention. 7-pitch pinion which quired min. was cut sec. Only min. was necessary complete 6-pitch The gasher arranged handle different types bevel gears. Elsewhere the plant are found other machine tools developed for its own exclusive use. Inthe table department, for instance, are five special milling machines. The old ma- chining setup tables consisted roughing slab miller, and finish- ing The new setup calls for the table first five spindle milling machine, with three vertical and two horizontal spindles. The top and sides the table are milled one pass requiring about min. time | against approximately min. time previously. The three vertical spin- dles are arranged that total width in. can milled one pass, though the average table only in. wide. The second table operation formed another special milling ma- chine with two vertical spindles and one large horizontal spindle, which mills the relief between the dovetails. The two vertical spindles semi-finish the dovetails. Operation three the table calls for finish milling dovetails and bearing surface, and finish milling machine, T-slotting performed the next special machine. The standard table has three top slots and two slots one ENERAL view the column department. New paint and sanding booths are left. far end bay, where canvas hung, another addition was being con- structed when this picture was taken. T-slot cutters and gash slots. Chips are picked exhaust sys- tem, nozzles being attached the spindle head and following the gash- ing cutter. Nozzles are attached each side the horizontal spindle which cuts the side T-slots. The ex- haust system removes 11.3 cu. ft. chips hr. with capacity 825 cu. ft. per min. Since the T-slot cutter shank fits into the gashing cut with only 0.002 in. all chips must eliminated. The top and sides the tables are ground standard machines. completed table issues from this line about every min., per cent reduction time over the old method. Approximately $2,000,000 was ex- ings, the new equipment and the reno- vation the old plant. addition realizing more space, office space was enlarged ranged, 200 seat auditorium was constructed for plant meetings, sales conferences, were enlarged, and the experimental room moved and size increased. artesian well the plant grounds pro- vides deg. water, which has simpli- fied the job air conditioning the entire office building. THE IRON AGE, September 26, | | i \ Quality Finishes for the lessons ground into the manufacturer metal products during the last few hard years the importance putting the “right” finish the “right” product. has become generally recognized that in- herent quality the product not enough make sell its fullest market. Every product requires fin- ish which talks quality the language which every purchaser understands— economy this step may doubted, notable exception this practice the case some the private dwellings which use gold plated plumbing fixtures and hardware for their appear- ance, long life and the elimination of polishing and cleaning labor. While the does have definite advantages for highly selected type user. eye appeal. other words, quality product needs quality finish. The word without close definition leaves both the manufac- turer and the purchaser quandry. metal porcelain enamel that the best finish for metal article one which will perform the func- tion for which intended, protec- tive, decorative, both, for tended life the article. However, not always feasible provide the finish. some shorter-lived finish and rerew for example, many plumbing fixtures which are built last for decade more, have nickel and chromium plate which lasts only from about two five LEFT for products over wide cost range. Left—aluminum reflec- finished Alzac (an electrolytic oxide); right—a cadmium plated cup holder and paper clip. (Courtesy Philip Sievering, Inc.) BELOW finish varied colors aluminum articles the class. (Cour- tesy Philip Sievering, Inc.) Metal Products fact, city apartments, custom- ary replate the fixtures whenever the apartment rated, many cases the article may tor both these purposes, for example, ishes commercially available for con characteristics are listed the accom table. the cheapest class articles, for and store sale, the purpose the finish either slight protection for utility articles sales appeal. So, there bright tional purposes, such us copper on parts tools and dies prevent carbonization heat treatment; cathode sputtering fabrics, waxes, aluminum alloy tools, dies and reduce wear, ete Such work, however, will not be imeluded in this discussion, ° ADOLPH BREGMAN Engineer, New York ° ° ° INETEENTH Series Articles the Technical and Economic Aspects Metal Cleaning and Finishing plate wiped with drop black imitate matte finishes, ete. The are often the merest flash the base metals, copper, nickel, chromium, ete. The coatings are mainly hot-dipped zine and tin, paints and light electroplates zine cadmi- um. The finishes which can used plates the base metals, hot coats, lithographing, paints, porcelain enam- els, and straight polishing. must borne mind that the inclusion these finishes the LEFT LATE non-metallic ar- ticles the more expen- sive grade. Left—bronze plate glass candle- stick; right chromium plate glass decan- ter. (Courtesy Philip Sievering, Inc.) and class does not stamp all them intrinsically cheap “bad” finishes. Some them greater care application, increased thickness deposit, are eminently suitable for higher priced articles, and are usable and finishes simply because their methods application allow con- siderable latitude. this class many the same fin- ishes used the and class will appear, but they will have definitely distinguishing characteristics. The pro tective coatings will heavier and will serve for decoration well. The decorative coat will real—not imi tation. Gold, silver and rhodium plate may Plating colors and varied color effects noticeably com- ing in. Chemical colors, oxides and sulphides will uniform BELOW latest word metal decoration —color plating gift ware. The ash tray the right hand corner color plate with iridescent effects, ap- plicable all (Courtesy United Chromium, | | p 4 ¥ 4 7 Dyed oxide coatings aluminum will non-fading and the prints, finish made stain-resistant. Bare pol- ished surfaces will free from polish- ing marks. Decalcomania will prop- erly centered. Colors lithographed printed coatings will correctly superimposed registered. Bezels watch cases will Organic coatings will special types withstand the materials which they are exposed. They will uniform thickness, they have runs “orange effects, and they will firmly adherent. highly flexible lacquer will used for arti- cles which may bent during service. oil resistant lacquer for the cover cosmetic jars, cold cream contain- ers, etc. All these properties will pro- vided within the limits allowed the price. The finishes applicable this class are chemical colors, chemical rustproofs (as undercoats), electro- plates (including precious metals), clad metals, hot-dip coats organic coatings, lithographing, paints mul- tiple coats for outdoor service, sprayed metal and straight polishing pre- cious non-tarnishing metals. Dollar Plus Finishes covers wide range. The prices there- might conceivably range from for novelty item $25 for elec- trical appliance. might also include precious metal jewelry, selling much higher the intrinsic value its raw material well its appearance, fin- ished only polishing the metal noble and consequently self-protective The improvements the finishes previously described for the sellers apply here, but greater measure. The products will expected have long life consequently the finishes will have even more carefully and heavily applied retain their appearance for longer time. “Specification’’ plates appear this class. Gold, silver, rho- dium, color plating varied effects. art enamels and the finest organic fin- ishes multiple coats and varied tones and colors are the most conspicuous. There will found few examples chemical colors, hot-dip coats, paints, lithographing bare polished surfaces except where the parts are precious metals. The finishes applicable here are chemical rustproofs coats), electroplates, clad metals, or- ganic coats, porcelain enamels and sprayed metals. Protective Finishes Although all coatings (even those pri- marily decorative) act protectors, 30—THE IRON AGE, September 26, 1940 Finishes Chemical Colors Oxides, Sulphides, etc. Chemical Rustproofs Oxides, phosphates, etc. Electroplates Copper, zinc, tin, nickel, cadmium, chromium, combinations, precious metals, color plates, electrolytic oxides (clear and dyed), etc. Precipitation coats (without current) copper, tin, silver. Clad Metals Precious metals Decora- Protection tion Low; must Good. pro- tected clear organic coat. Not great; Fair must blues and protected oil film. Main use— undercoat for organic coatings and paints steel Good Good. heavy deposits the proper metal. Low; coat- Fair ings are good. very light. Good. Good, but too ex- pensive for deco- ration only. FINISHES FOR Characteristics Finishes Various Classes and Light coats, short dips. Blues and blacks steel. Light de- posits base metals; plates. Tin brass pins, screws, electrical terminals, etc. Silver mirrors. Not used. filled; Over Uniform, clear colors, free from tions, non-fading, etc. Same class. Undercoats Same organic coatings steel. Substan- tial class. deposits including precious metals; fine color plating effects. Same Silver mirrors; heavy coats, well backed with copper plate, lacquer, enamel, Gold Same class. Sheffield plate. | METAL Finishes Hot Dip Coats Protection tin Good heavy deposits. Organic Coats Lacquers, Good synthetics, properly enamels, chosen for varnishes, specific japans, etc. Lithographing None. Printing, Decalcomania, etc. Paints Good. Porcelain Good. Enamels Sprayed Metals Most com- Good. mercial base metals Polishing Little Only none, except stainless steel. PRODUCTS Decora- tion Not used. Good. Good. Fair. Good— varied colors, etc. Good for special purposes, art ob- jects, etc. Good attractive metals. and Light coats. Plain colors, one coat, air dry; varnishes, japans, etc. Simplest, cheapest type One coat, simple work, Small kitchen utensils Not used. One two operations, low cost Heavy coats, "Seal weights, etc. Baked synthetics, two coats, etc. Good registry, careful printing. Not often used, ex- cept for articles subject outdoor use, rough handling, multiple coats. Kitchen utensils, heavier coats, colors. Some special novelties. High polish, free from emery marks, etc., non- tarnishing metals. Characteristics Finishes Various Classes Over Same Special formula- tions, various tone com- binations, coats, Not often used. Same class. Art objects, statuary, large pieces. Art objects, large pieces. Rarely used except precious non- tarnishing metals. greater lesser extent, many products are coated, mainly for protec- tion against wear and corrosion—that is, against physical attack. Wear service involves abrasion, and “hard knocks.” withstand wear, the finish must hard and tough resilient. Resistance corrosion calls for resistance the chemical attack mediums ranging from mild chemical. The purpose the finish protect cheaper non-resistant basis material. consumer products, the finish must receive the seemingly slight but often recurring, and some instances almost constant, abrasion human hands, cleaning and for instance, door knobs, building and automobile hardware and kitchen im- plements. The corrosion which the finish subjected mainly air, soap and water, although often food prod- ucts are involved. industrial prod- ucts, the service may many times more severe: acids, alkalies, salts and almost all the infinite variety in- dustrial chemicals manufactured and incidental plant this field, therefore, specifications are most common, fact indispensable satisfactory performance. Porosity may checked maximum number visible pores al- lowable under specified porosity test. Thickness weight deposits can specified and checked variety tests. Once the proper standards have been determined, the problem simpler than purely decorative coat- ings where the personal element plays such large part. Compare, for in- stance, specification for minimum thickness 0.001-in. nickel plus cop- per automobile bumper with demand for “gold finish soft greenish 14K color with just little bit antique smut—but not too Which directions would the producer rather follow? specifying the The most important protective fin- ishes are chemical rustproofs (as undercoats electroplates, clad metals, hot-dip coats, organic coats, paints, porcelain enamels and sprayed metals. vs. Quality The inexperienced reader may confused find that most finishes are used both high and low priced arti- books covering this broad subject are “The Corrosion Resistance of Metals McKay and Worthington: and “Protective Coatings for Metals,” Burns and Schuh. THE AGE, September 26, —_, ; cles; that many finishes have noth- ing inherent stamp their quality. This true. Some finishes may appear articles and $25 arti- cles, such chromium plate, for ex- ample. The answer that the plate the $25 product vastly superior the plate the item. The plate for the cheap article may only flash directly the basis metal. The quality plate likely consist nickel coat, thick, copper and nickel the same total, covered finish will firmly adherent base and free from porosity. Conse- quently the finish will have not only good appearance the time the purchase, but will also and long lived. Adherence the basis metal can obtained correct practice; proper preparation, cleaning, and application under correct conditions. Freedom from porosity depends partly upon good finishing practice and partly upon the thickness the coating, although some remarkable work has been done Hothersall and Hammond, ducing pore-free deposits very light The life the finish, given adhesion and minimum porosity, de- pends very often upon the thickness the coating, and for this factor there are guides the form tions. Specifications the War and Navy Causes Porosity Electro- deposited Coatings, Especially Nickel the 73rd general meeting the Ameri- Electrochemical Society, April, 1938. figures should not taken too well known that the salt spray test gives varying Departments will indicate offices require the way quality when they purchase great variety finished articles. Federal specifications (obtainable from the Superintendent Documents, Washington; see price list 75) will worth while, especially the group which include metal products and the which include plumbing fixtures and pipe fittings. The Federal specifications for finishes plumbing such chromium plated bathroom tures, switch plates, curtain rods, The American Society for Testing Materials has designated standards for many coatings, such nickel. chromi- um, cadmium, zine, and methods testing for quality desig- nations: plate steel part will find that combined thickness significant sur- faces copper and nickel deposits least desirable for out- door service and for indoor mild service. The minimum thickness chromium both cases would the same, since the corrosion resistance chromium deposits thicker than about and may even decreased the deposit too heavy. Its value lies the maintenance non-tar- nishing These should also stand for least hr. and 16° hr. respectively the continu- ous salt spray apparatus. The manu- facturer will, therefore, specify these RIGHT fixture chemical colors (oxidized bronze) zinc-base alloy. high grade article for indoor use, with the fragile finish well protected clear lacquer. (Courtesy Lightolier Co.) ° BELOW plastic. This type finish applicable over wide price range, but more likely found the better grade articles. (Courtesy Philip Sievering, Inc.) minimums and perhaps even increase the requirements one-third more the safe side. porosity test usually indicated for all coatings except electronegative metal coatings which have sacrificial action. The salt spray which gives some indication poros- ity. Various other tests will found the literature and Government specifications. porous and should stand certain tests depending the use which the coatings are put. Among such tests are abrasion, adhesion, bend, im- pact, discoloration heat and light, chalking and flaking exposure the atmosphere, resistance various chemicals such acids, alkalies, chlorides, alcohol, fruit juices, ete. The complexity the problem due the range choice finishes and the special requirements the arti- cles, may shown some examples. Thus what would considered very good tin coating diaper pin, would entirely out the question refrigerator tray. The pin falls into the cheapest group and not ex- pected have long life. immer- sion tin deposit generally quality tin coating