The Iron Age 1940-11-07: Vol 146 Iss 19

1940 VOL. 146 NO. VAN DEVENTER President and BAUR Vice-President and General Manager Managing Editor News Editor Technical Editor Machine Tool Associate Assoclate Editor Editor Editor Art Editor Editor Emeritus Washington 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 Newark, Editorial Now That It’s Over Technical Articles Setting Price for How Bend Tubes............. Heat Treatment and Process Control Equipment...... Feature Reports the Assembly Line News and Market Reports News Industry Machine Tool Activity 122 Personals 108 Non-Ferrous Market 123 109 Scrap Market and 124 Comparison Prices 112 The Industrial Pace ... 114 Warehouse Prices District Market Reports 116 Sales Possibilities Copyright, 1940, Chilton Company DIX, Manager Reader Service Owned and Published (Incorporated) Advertising Staff Publication Editorial and Emerson Findley 621 Union Bldg., Cleveland Office Executive Offices Herman, Chilton Philadelphia Chestnut and Séth Sts., East 42nd St., Hottenstein, 1012 Otis Bldg., Chicago Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd St., New York Park Pittsburgh OFFICERS AND DIRECTORS Don Harner, 1595 Pacific Avenue, Long JOS. HILDRETH, Vice-President Beach, Cal. GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President Member, Audit Bureau Circulations BAUR, Vice-President Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- WILLIAM BARBER, Treasurer lished every Thursday. Subscription Price: JOHN BLAIR MOFFETT, Secretary United States and Possessions, Mexico, Cuba, JULIAN CHASE, THOMAS KANE, $6.00; Canada, $8.50; Foreign, $12.00 year. Cable Address, HARRY DUFFY CHARLES HEALE | ' | bass 78 202 | wit Immediate Shipment Assured The ability deliver promptly is, course, outstanding impor- tance today, but Ryerson offers still more. The buyer who may need angles, sheets. welding rod, and many other items assured uniform high quality regardless the size his order. Under the Ryerson Certified Steel stocks include only selected products that meet the most demanding specifications. The purchaser can then concentrate orders for practically all his steel requirements, securing uniform high quality and quick service saving time and money. Ryerson certified alloy steels are outstanding example the care used the selection our stocks. assure entire heats 150 tons) alloy that meets our narrow range specifications are secured. Bars are analyzed and tested for chemical and physical properties and heat treatment response. Every bar clearly identified with the heat number. Data sheets and charts showing properties the steel and results the tests are prepared and sent with every order, large guide heat treatment. This valuable service given extra cost. Ten large Ryerson plants carrying more than 10,000 kinds, shapes, and sizes steel products stand ready meet both your regular and emergency requirements. you not have the current Ryerson Stock List. shall glad send copy. Joseph Ryerson Son, Inc. Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. 40—THE AGE, November 1940 r > ¢ | é ; 5 al Oo NOV. 1940 ESTABLISHED 1855 Now That It’s Over--- that it’s over, can all breathe sigh relief and settle down the business hand. And this includes the next President. one need envy him his job. the toughest one faced any our Presidents since time. going need all the help that can get from every man and woman the United States, and believe that will get it. Feelings ran high during the campaign and some unpleasant things happened. They generally when feelings run high. Unpleasant things happened, even more them, when Lincoln ran for office. But now these things will forgotten, for that part the American way life. take our ball games and our elections seri- ously. are extreme partisans while the contest going and some- times some hurl epithets and even pop bottles the players. But after the series over and some team wins the pennant, forget all about it. Emotionalism ran particularly high during this campaign because the whole world has the jitters. nation and its people could possibly escape the psychopathic effect the European cataclysm, however re- mote from it. were afraid being drawn into this cataclysm, drawn into not being able survive it. Hence the partisan- ship and the eggs and onions and epithets. They were not directed either candidate; they were being hurled Hitler. Every citizen who voted for Mr. Roosevelt undoubtedly believed that was the man who could save America. Every citizen who voted for Mr. Willkie undoubtedly believed that was the one man who could and would it. But neither belief was correct. President can save destroy his country. takes the people that. Our big job now save America. make strong that enemy America, from within without, can destroy it. That job which calls for the best efforts united people. For the next four years, change the name our country. call the United People the United States. | | > fi ‘te | | | Sheet Forming and Fabrication Costs Reduced! Many manufacturers are cutting production costs, making finer products, and beating competition with Inland special sheets and strip. They get these results be- cause Inland metallurgists determine the kind sheets best suited their purpose —and, then work with the mill produce the exact sheet specified. Users Inland Sheets can definitely count superior forming qualities, constant uni- formity, and fewer rejects, from beginning end production runs. Inland metallurgists, with their broad ex- perience, will also pleased help you developing tailor-made sheet strip that will lower costs and improve your fin- ished product. This Inland service yours for the asking—without cost obligation. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATES STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS J } Dearborn Street, Chicago Offices: Milwaukee, Detroit, Kansas City, Setting Price for Plating ADOLPH BREGMAN Consulting Engineer, New York —Demonstrating the wide difference between price set hard pur- chasing practice and practical time study old story that great deal quick inspection the article. more the chosen few will shrug his contract work every line Some are foolish enough and shoulders and say, “Well, someone being done today barely cost, variations quotations may else can it, ought able to. “in order keep the wheels turning.” wide 300 per cent. The wiser bid- Give the order.” receives Especially this true during the dull ders ask for sample lot try out order for substantial quantity and seasons the year when felt nec- before quoting. goes essary take almost any job order The purchasing agent sends sample the first lot, finds, after figur- keep working force together. lots chosen half dozen bidders ing his costs, that has lost money, Shrewd manufacturers have learned (including the lowest, regardless complains bitterly. But the pur- take advantage this situation stability). Shortly thereafter the Chasing agent, being wise the ways having work made for stock agent collects his quotations, including sellers well the art pur- the off seasons, substantial those who have quoted sight and chasing, suggests that goes with the job, his production rates will This practice is, course, legiti- then calls two more the most improve, and since very big job, mate; good business. the con- reliable platers and offers give them will undoubtedly show substantial tract shop wants take work prices the work the lowest price quoted, profit over-all. the plater takes an- which makes profit, his regardless the reliability the other lot. then finds out that “privilege.” However, quoter. The platers who are offered has again lost money, but perhaps not practice has crept into the industry the work take solemn oaths the squauks again, the which not good business, but sharp effect that cannot done such conversation repeated and takes business. consists getting prices figures, but the purchasing agent shows another lot. from variety suppliers, and them bills (of course, hiding the name This process repeated with one large, stable and unstable, reputable the biller and showing only the more additional platers and time the and even “shady,” order set price). far too many cases one whole job completed and none mark for the platers show profit. recently came Technical and Economic Aspects Metal attention the writer, Cleaning and Finishing who was called cedure. The purchasing agent typical method sample. They are asked contract plater quote “immediately,” vestigate job which THE IRON AGE, November 1940—43 > | a | f x A, | ‘ felt was unprofitable. plater expressed himself wide open suggestions any kind. Perhaps his methods called for revision. had been the plating business only years, perhaps did not yet know thoroughly! Perhaps his cost fig- ures were inaccurate. Perhaps—per- haps anything all. wanted find out what was all about. result, test run was made lot 100 chandelier holders shown the accompanying illustration. examination the holders, which were made cold rolled steel, showed that the following operations were necessary order obtain the de- sired finish. (1) Grinding with No. 120 emery. (2) Polishing with emery flour. (3) Polishing with tampico brush. (4) Rack for copper plating. (5) Degrease. (6) Clean alkaline cleaner. (7) Rinse. (8) Copper plate. (9) Rinse. (10) Dry sawdust. (11) Unrack. (12) Buff the copper plate. (13) Rack for nickel plate. (14) Clean alkaline cleaner. (15) Rinse. (16) Pickle. (17) Rinse. (18) Nickel plate bright nickel solution. (19) Rinse. the development these methods, see Finishing Adolph Bregman, Tue Iron March 28, 1940, pp. 28-31. IRON AGE, November (20) Unrack. (21) Rack for chromium plating. (22) Chromium plate. (23) Rinse. (24) Dry sawdust. Buff chromium plate. The article was then ready for pack- ing and shipping. was decided time the above operations detail, obtain the com- plete direct labor cost, which would added the regular overhead bur- den this particular plant which would include the packing ping. The job was given clear track HANDELIER holder cold rolled steel. This copper, nickel and chromium plated. What should the price the plant; other words, other work was permitted interfere with it. The men were told that this was test run and instructed thor- oughly good job, but work their regular pace, which could carried day and day out, order give true picture. Actually, the result these instructions was that the men did excellent job, good that pieces were rejected under the most careful inspection; but they tially faster than their regular rate and which, the writer’s opinion, they could not keep day after day. worked pace which was substan- other words, the figures were the hest that could obtained the men had already had experience with this work and were going their very top speed, “putting show.” The time records are shown the accompanying table. should noted that the timing number the operations was combined was not practical segregate them. So, for example, operations inclusive, covering racking for copper plating, all the way unracking, are lumped together the copper plating opera- tion. Similarly, the bright nickel plat- ing operation includes operations inclusive, and the chromium plating operation includes operations inclusive. The selling price may determined Direct Labor selling price. 5.12 2.5 $12.80/100 pieces. (2) Total polishing time per hr. Operation |—Emery min. 2—Flour min. 3—Tampico min. buff min. 24—Chrome buff min. Total 236 min. min. 4hr. The price which the plater had been receiving for this job was piece. order make sure that possi- bilities were being overlooked, was decided attempt eliminate the emery flour polishing (operation No. from small number pieces, order reduce the cost. (In this in- stance 88c. per 100, which together with overhead and profit would have meant reduction 2.2 cents per — piece.) other words, half dozen pieces were ground with 120 emery and then polished tampico brush, copper plated, buffed, etc., etc. difference was noted until the bright pleted, after which these half dozen samples were spotted instantly the presence speckled appearance in- stead the desired high luster, espe- cially the rim, the edges and the fillets where the deep draw had opened the surface the steel. Consequently, this attempt cost reduction was failure. The possibility was also dis- cussed substituting greaseless pol- ishing operation for two more the three polishes employed, but trial few pieces showed this unsatisfactory. Other methods cutting polishing costs (always the largest item metal finishing job) also came under discussion. was obvious, however, that the quantities involved this job made automatic polishing impractical. The total volume involved was approx- imately 100,000 pieces, sent lots 5000. There was assurance any time that the job would run long Time Pieces Emery 95¢ per hr. min. 88¢ (2) Flour 95¢ per hr. min. 88¢ (3) Tampico 90¢ per min. 90¢ (4-11) Copper Plating: Plater 80¢ per hr. min. 40¢ Helper 40¢ per hr. min. 20¢ (12) Copper Buff 95¢ per hr. min. 72¢ (13-19) Nickel Plating (Bright): Plater 85¢ per hr. min. Helper 50¢ per hr. min. (20-23) Chromium Plating: Plater per hr. min. 23¢ Helper per hr. min. (24) Chrome Buff 85¢ per hr. min. Total Direct Labor $5.12 per pieces enough amortize the cost auto- matic polishing machines. The same course, automatic plating machines. was, all the polish- ers were provided with special hand chucks fit the pieces, allowing them turn freely under control the experienced polishers, get the maxi- mum speed possible hand, consis- tent with satisfactory work. must repeated for emphasis that the opinion the rate shown the above table was probably greater than the expectable day-in production. The outcome this test was that the plater shortly thereafter paid call his customer and declined, with thanks, any more this work What did the customer when con- fronted with this ultimatum? would pleasant report that saw the light and was willing pay fair price. this instance, however, being abound, could always find someone else who was willing “keep trying,” still getting his work done less than cost. For that matter, accord- ing latest reports shopping around for even lower prices Steel Corrosion Molten Nitrates corrosion steel containers molten alkali nitrates im- portant the heat treatment aluminum alloys salt The process has been investigated laboratory scale Lloyd and Chamberlain, and reported recently the Iron and Steel Institute The corrosion steel molten alkali nitrate was investigated with special reference the effects tem- perature and impurities the salt. was found that the scaling which takes place under these conditions different both character and ex- tent from scaling gaseous medium the same temperature. Although the rate oxidation increases markedly with rise temperature, local heating part the metal container does not itself give rise abnormal scal- ing that point. tests certain irons and steels showed that Armco iron had high resistance this form corro- sion; investigation this aspect the problem continuing. The protec- tion provided aluminum coatings was uncertain. Alkali chlorides are common impurities the commercial salts used for the heat treatment light alloys, and was found that they are responsible for marked accelera- tion the rate attack the steel; 0.1 per cent exercises considerable influence. was found that decomposition nitrate nitrite does not proceed completion and that salt mixtures con- taining much nitrite are oxidized the atmospheric oxygen. one series tests with sodium salts 500 deg. and air the equilibrium concen- tration nitrite was found about per cent. was concluded the investigators that with the sodium salt the presence per cent more pressing the corrosion, but with the eutectic greater addition may necessary account the lower in- trinsic dissociation temperature. THE IRON AGE, November 2 =, | | ; = | | | | | ¥ UCH the material used the manufacture locomo- tive and car parts the Nor- folk Western Railway smith shop Roanoke, Va., remanufactured the smith shop itself from scrap ma- terial both wrought iron and steel so-called welding quality. this meant that scrap material actually remanufactured into billet, bar and narrow plate form, and not simply that waste crops from the plate shears, for example, are sent the cutting torch shape for some particular part ap- plication without reworking the metal The process used not much dis- from that used wrought iron the old method. will recalled that making wrought iron dling, after the pig iron freed from impurities and the purified iron ob- tained the form ball, the latter squeezed expel most the slag and rolled into rough bars, designated muck bars, No. iron. The muck bar then sheared into small pieces, heated welding heat furnace, hammered under steam hammer and sometime later rolled into the shape desired. This process known busheling and the product called hammered bloom iron. More usually, however, the muck bar sheared into short lengths which are piled one upon another, bound wire, heated welding temperature and rolled into bars. known No. single rolled iron. 46—THE IRON AGE, November Forge Sho Practice For further the No. iron sheared into lengths, piled, reheated and rerolled form No. double refined iron. Railroads still use appreciable quan- tities this material. fact, most the wrought iron reworked the wrought iron scrap welding quality steel scrap, that is, dead soft, low car- bon plain steel. The iron steel the form plate scrap, reduced shearing necessary average size 4x6 in. and averaging in. thick. About 400 Ib. these scrap pieces piled overlapping fashion ing temperature powdered coal fired furnace. Usually the first batch placed the furnace the end shift and left overnight, the night watchman turning the furnace full heat the early hours the morning. See Fig. the morning the pallet with- drawn and the material brought 4500 steam hammer. The first operation attach staff, Fig. Then the piled scrap “singled” in. thick. The slab next cut two with tool, forming two “chunks.” These chunks are allowed cool before being piled top each other, are reheated, restaffed and Practically the same process lowed for the forging quality steel. Such steel wrought iron slabs are powdered coal fired under the later worked down form locomotive parts, most them stress carrying members, such driv- ing box equalizers. That the reworked material high quality attested the fact that much must pass Magnaflux inspection for internal pipes, seams and flaws. The economy the process found the difference the average sales price No. wrought iron scrap (about and new double-refined wrought iron (about 6c. Also, this reworking old material helps maintain the naces operation well the large hammers, not overlook the crew men. other words, this work ab- sorbs some the overhead burden fixed charges what might otherwise partially idle equipment, besides providing steadier employment fur- nace and hammermen. The driving box equalizer, Fig. typical highly stressed steel part successfully forged from salvage ma- terial. Welding quality steel singled into chunk, then doubled into billet, which later reduced thickness suit the particuar part—in this exam- ple in. thick. will noted from the part sketch, however, that each end there are bosses in. (sometimes in.) thick and the central sec- tion there rocker bearing plate in. wide. and > > & stec . shaping for the bosses done upsetting forging machine while the inside rocker extension piece ham- mer-welded with the aid special die. might asked why the rocker extension could not have been formed folding over the edge the flat stock. For the particular equalizer shown, this not possible because the depth limitation the forging machine, which in., whereas the overall rough forging depth mately 10% in.; hence the necessity tacking chunk later. the process, the slab first cut ting machine using suitable templates. This equipment located side bay the smith shop. For reasons backing the piece during the up- setting operation, the rough outside contours the unformed center. bosses are Sufficient metal left gather the boss boss centers are bent down tangent the rocker base for the completed part. being standard item, are put through sizeable lots and one end upset time before the position the backup post changed for upsetting the other end, This upsetting done two stage die, the flat the work being held horizontal plane for furnace with scrap iron steel pieces which are later forged into chunks seam hammer. turned deg. into vertical plane for the second and final upsetting opera- tion. The taper leading the bosses also shaped the second cavity. Hammer Welding Next step hammer weld the rocker piece under leg ham- mer using the special step die shown Fig. This die, which the form double 45-deg. step, not only completes the hot juncture the met- als, but also forms the 24-in. radius the rocker, job previously laborious- performed shaper. The only finishing required this rocker now rough grind with portable pneumatic grinder in. the machine shop. Final forging operation bring the boss centers down into line with this rocker crown and form the inside radius the equalizers the same time. This readily accomplished hot steam drop hammer through the use form shoes sup- ported laterally fixture. The equalizers are then matched pairs and sent the machine shop for drilling the bushing holes and grind- ing the rocker radius. estimated that about per pair equalizers saved over the former method tak- ing heavier stock and working down steam hammer instead AMMER squeeze weld- ing used extensively building locomotive and methods, employing both steam hammers and upsetting type forging machines. Con- siderable the raw material used the smith shop Roanoke remanufactured under the steam hammer from scrap wrought iron and welding quality steel. FRANK OLIVER Machine Tool Editor, The Iron Age employing hot-heading and putting-on methods. Welding Hot Header Another example putting met- hot heading operation the building the bosses the facing stems the Pitt coupler used cars. Building metal total depth from in. flat stock too much expect from any upset forging machine unless done number stages, two more set- ups. Instead, the smith shop, filler pieces are laid each end shown the sketch, Fig. welding compound used flux lay the scarf and forging heat sufficient adherence obtained from the weight the piece enable the parts carried the upsetter without the filler piece dropping off. will noted that the square boss the right end offset all one side the flat. the first impression the forging machine die, however, the initial gathering and welding dis- tributes the metal fairly well about the centerline the flat blank. the second, reheading die, one side (the lower, the sketch) pushed back into line with the side the stem, thus raising the boss its finished height. This piece was previously roughed out from heavier stock forging ham- mer and then machined. With the present procedure, there machining done this piece except drill the bushing holes indicated and THE IRON AGE, November 1940—47 | i | ‘ > | | | | | 4 | : ABOVE 2—Scrap wrought iron steel welding quality remanufac- tured under this steam ham- ations. The long staff (about ft.) protects the hammer men from flying scale. drill and countersink few rivet holes not detailed. The length the fin- ished forging determined the po- sition the backstop the forging machine. Making Spring Bands Another example welding type forging machine shown Fig. This locomotive spring band with rocker eye made two pieces flat stock bent into U-shape. Piece first deeply indented marked for the bends piece spring bent into U-shape with one leg longer than the other, the longer leg being used handle. Then the two ends the thick material are knocked down in., drawing them out and rounding the ends Depth dimension in. control- ling one, and determined during the 48—THE IRON AGE, November Enlarged view end equalizers showing radius inside corners ABOVE 3—Details typical locomotive driving box equalizer. Highly stressed engine parts like this are forged out remanufactured raw material. BELOW 4—Special step dies are sometimes used assist on" metal. the example shown rocker bearing boss being attached driving box equalizer the forma- tive stage after the ends have been upset. upsetting (which effect assembly opera- tion pieces and stake over which the hot pieces are slipped. make job like this possible 4-in. forging machine, the toggle mechanism disconnected and the side holding dies removed. The upsetting operation not only forms the semi-circular ends the projecting lugs, but also com- pletes the weld between the adjoining faces, the same time filling out the thickness the lugs 134 in. indi- cated the drawing. Still another example building material pressure welding and — | “ly Parting line header for bushing forming upsetting machine given the spring band, Fig. Total metal thickness the rocker contact boss in., yet this piece built from in. stock. Overlapping not sufficient build the thickness more than in. less, consider- ing the effect upsetting. Hence small filler plate introduced between the overlap the original flat stock. This filler piece must held tion prior welding filler plug inserted hole cold punched both the filler and the end the stock. The upsetting operation completes the surface welds, welds the plug and forms the 15-in. rocker radius. Mate- rial welding quality steel. Building Worn Parts Draft gear side links fail crack- ing through the reinforced hub the ends the slots, shown the part cedure has been adopted for building each end this point with new metal. welding quality steel in. laid the end which then brought welding heat open front furnace, and the reinforcing hub reforged 4000- steam drop hammer. The die em- ployed purposely made oversize that the excess metal goes into widen- ing the piece well filling the slot. The work trimming the sides and end, punching the slot, straightening the link and embossing the date reclamation the flat all performed crank press extra width accom- modate three dies row, making this progressive operation. shown Weld line. for bosses this Pitt coupler stem are built filler pieces prior hot upsetting. Fig. the trimming die the center, punching die set the left and stencil and straightening die the right. The latter spring backed double action die. practice called for straightening the side links hand and punching the slots cold. pair made over the manufacture complete link from new material. The same equipment course available for manufacturing new side links. Die Forging Gas Cut Parts good example where gas cut- ting and drop forging costly machining operations the manufacture spring hangers and spring shackles for tank tenders. can seen Fig. 10, the part has rectangular shaped yoke which the wall sections are not all straight, one having semi-circular face. the spring shackle has threaded shank) there are two facing sections 19/16 radius place only one the spring hanger. The mate- for 6—Spring band with rocker eye. This piece formed from two flats bent shown U-shape and pressure welded upset forging machine. rial reclaimed steel and forged from remanufactured chunk in. thick. The rectangular hole cut out with torch, starting from drilled hole. Previously the radius was formed the machine shop rough- ing out with slotter, chipping with air hammer and finishing with portable grinder. The labor alone cost about $4. Now this piece fin- ished matter minutes after the oxy-cutting operation through the use relatively simple drop hammer die. The piece laid its flat side and the parting line through the middle indicated. The extra stock thickness used fill out the radius, and trimming the part hot, the Detail stock end before bending 7—Another type spring band formed from flat stock and even- tually consolidated hot upsetting methods. THE IRON AGE, November 1940—49 / 3 27 rad. ' ” Ts ° ° ° d : = } q ” | 8, | ABOVE 8—Typical draft gear side link that built after wear service putting-on material the hammer welding method. tools are used this double crank p-ess perform trim- ming, punching, straightening and embossing progression draft gear side thin nut corners IRON AGE, November BELOW these trailer spring hanger yokes became badly worn ser- vice. restore the surface for the threads, two pieces steel in. are wired the shank, brought forging temperature and knocked down cylindrical shape. tan ABOVE 12—Swing center hangers are rough forged under the steam hammer out remanufactured chunks and are later finished drop hammer dies. Practically all chining operations have been eliminated. ABOVE 13—Forging methods this spring hanger link have been modified reduce subsequent machining operations minimum. LEFT IG. spring hanger for tank tender has the opening the yoke cut out gas torch and the sides finished drop hammer die, replacing large amount previous costly machining operations. | O ” Ss 3 | 4 ~ i ~ are | | - 5 X & A > forging draft removed the outer sides the yoke. These were previ- ously machined. Flash the parting line inside removed the same time. the job now set up, the only machining operation required that threading the shank. This done directly from the forging, with prior turning the o.d. swing center hanger, 12, another piece forged out salvage material. Because the heart shape the piece possible get two blanks out one chunk forging the staff alternately each end. The blank rough cut shape the hammer with the aid steel template, and then finished drop hammer die. material goes into thin web section the center the piece well the flash the outside. The outside profile trimmed hot press and the center section punched out hot with loose which also removes the draft angles the rocker bearings. The only machin- ing operation necessary drill the hanger pin hole the top, locating this hole template engaging the two hanger pockets. Machining Operations Reduced Wherever possible, forging opera- tions are performed such manner reduce subsequent machining op- erations minimum. The spring point, forging that knocked out two drop hammer dies and trimming and punching press. The roughing die has three impressions, one impression used nick the in. billet before breaking down the flat shank the piece flat The third impression rough shapes the rounding the end. finish die has single impression, leaving but small amount flash around the part- ing line the die halves, which are identical. should noted that the piece laid the die that the draft angles come non-critical surfaces. Originally the piece was parted the die deg. the present position and this left the draft angles the pin boss faces, necessitating later ma- chining operations. These faces need not machined with the present set up. second section the die. Handy Bending Press Though there not enough work keep this particular machine daily use, 200-ton horizontal hydrau- lic benching press stalled few years ago has proved extremely valuable tool. has sufficient capacity bend the heaviest IG. Special fixture devised for forming coupler yokes 200-ton hydraulic press. rails hot. Aside from track work, such rails are used, for instance, making curved side stakes flat cars con- verted for carrying pulp wood. been bent this machine hrs. An- other typical job forming coupler yokes. special fixture has been built for this work which has number advantages. shown the photo- graph, Fig. 14, the fixture scissor- like arrangement with adjustable toe holds each arm constrain the ends the yokes while they are being formed from the flat. The pivot point slides against spring pressure and the initial action the links attached the special crosshead (which manently fixed the press ram) close the scissor armis, thereby put- ting the piece compression and bending, the reaction being taken against the movable pivot point the back side the yoke. Final forming with interchangeable radius blocks the arms done against fixed stake post bolted the press bed. apparent that this type bend tends thicken the yoke sections the bend radii end compression, which absent when hot work wrapped around post. Other jobs worked this hydrau- lic bending press the hot forming large crane hooks around anchor blocks, also the cold bending T-iron sections such are required tender tank roof construction. Comple- tion the closing action the fixture the yoke arms, the starting motion which was shown Fig. 14. } BEY } TAINLESS steel rolled section bent after being embedded buckling spreading. ITH the rapid growth the use thin wall tubing many fields, particularly the aircraft industry, manipulation prob- lems have become major impor- tance, and the production perfect bends has been matter increasing difficulty. Many materials have been used fillers tube bending with certain measure success. Resin, pitch, sand, lead, spiral springs and internal man- drels have been satisfactory point preventing buckling, flatten- ing rupture the tube wall, but frequently fail when the bend required has been any degree acute, when the gage the tube wall has been light. Sand difficult pack tightly enough give sufficient support the tube wall. Lead has setting shrink- age which results comparatively poor support, and, further, its high melting point precludes its use with light alloys. Resin and pitch have given fairly good results, but fail The use bismuth alloy for locating and securing die parts was described THE IRON AGE, issue Feb. 1940. 52—THE IRON AGE, November 1940 the sharper bends, and addition are messy and not little dangerous handle. Spiral springs mandrels are, general, limited use the gentler bends. very serious objection all these fillers, other than the spring and man- drell, the difficulty experienced completely removing all traces the filler after bending. Small particles left the tube and coming dislodged may cause serious troubles service, left the tube give rise regions marked weakness after heat treatment. Cerrobend, alloy bismuth, lead, tin and cadmium, has peculiar prop- erties that make ideal filler for tube has extremely low melting point—i60 deg. much less than the temperature boiling water. has been used suc- cessfully the bending tubing with walls thin 0.007 in. small radii. This filler conforms snugly the inside the tube that the latter can bent though were solid bar. This quality due the fact that the alloy expands slightly instead con- tracting solidification. Molten Cerrobend and crystallizes slowly, resulting coarse crystal structure and quite brittle this condition. However, rapidly chilled, acquires fine- grained structure which very ductile. using this alloy for bending metal How Bend tubing, the alloy should put clean ladle and covered with water. point, which completely melts the Cer- robend. Prolonged heating should avoided this tends raise the alloy too high temperature. The boiling water poured off the top the ladle into the tubing, one end which has been closed tightly with cork other stopper. The hot water preheats the tubing and guards against cold sets during loading. poured into the tubing, displacing the lighter water. When the tube filled with molten alloy, plunged ly, corked end first, into tank cold water. This insures fine crystalline structure the alloy, which makes ductile and easy bend. has low thermal conductiv- itv, Cerrobend cools very slowly, even when water-cooled. After chilling, the tubing and its filler should allowed bending. Almost any type bending equipment can used the bends are made slowly uniform speed and uni- form loading. Too much speed un- even application power may cause failure. the case thin wall alu- minum duralumin tubing bent small radius, the bending should done multiple stages rather than all one time. Cerrobend may easily removed from the tubing heating steam bath, boiling water hot air tem- peratures approximating point water. The use bare flame not advised the tube wall mav overheated even burned. The metal can drained out the tubing molten condition and used again and again. said not occur, except under unusual conditions. can avoided dip- ping the tube light engine oil the molten metal poured into it. the tubes are oiled before loading there possibility the com- i “re 5 4 | ‘4 i H 4 | tas | fo} ° ¢ said that the alloy has found special favor airplane factories, for bending fuel, oil and hydraulic pipe lines. Tubes used for constructing air- plane frames are also formed the use Cerrobend. Tubes irregular section can bent readily round tubes. most valuable development the use Cerrobend the forming rolled extruded sections. The need complicated rolling machines for this work has been obviated. The pro- cedure cast the alloy suitable mold completely embed the section, and then bend the block alloy round former dimensions allowing for the thickness alloy surrounding the section. Under these conditions (par- ticularly the former grooved ex- actly accommodate the cross-section ODERN aircraft construction. All tubes shown this aircraft nose the alloy block and prevent any frame have been bent with Cerrobend. cross-sectional distortion), impos- sible for the section ripple spread any direction and perfect bends are ing into contact with the tube wall aluminum tube 0.25 in. achieved. since the chance the oil film being diameter hand wound broken the operating temperature round former with 212 deg. extremely remote. rippling buckling. Also, bronze carried out the Royal Aircraft tube 0.0035 in. wall thickness tablishment (England) for pressure gages bent with that alloying the Cerrobend with Cerrobend with complete ab- tube wall takes place and approval sence rippling. its use has officially been given the Ministry provided the tubes after un- loading are cleaned blowing with out any small beads Cerrobend which may retained the oil film and possibly cause interference during subsequent treatment. When the tubing too small diameter permit pouring the molten metal into it, the alloy can drawn into suction without trouble. This practice generally followed with tubes in. diameter less. The Cerrobend method has been ap- plied successfully the bending copper, brass, duralumin, and stainless steel tubes. Tubes plated with chromium nickel can bent without danger the plate flaking off. THE IRON AGE, November 1940—53 t % | = ie Flame Hardening Standardization standardization operat- ing conditions for progressively flame hardening steel parts much less involved than those encoun- tered for cast iron. This primarily due the fact that great deal information available concerning the desired heat treating cycles and microstructures for all the commer- cial alloy steels commonly used. With this information basis only necessary establish flame hardening conditions which will tures that duplicate those obtained when proper furnace hardening prac- tices are employed. conditions can readily established using series test the general design the part hardened. For example, series blocks having widths ranging from in. in. and the same general design shown Fig. (see Oct. issue) may hardened under various oper- ating conditions until suitable case depths and microstructures tained. The curve Fig. shows set conditions which will produce hard case 3/32 in. 5/32 in. deep. The photomicrographs Fig. were taken from specimen SAE 4145 steel flame hardened accordance with the data tabulated Fig. 20. The photomicrograph F-314-A shows the pearlitic base metal IRON AGE, November 1940 HARTLEY Metallurgist, LeBlond Machine Tool Co., Cincinnati three previous sections this five-part report, the author covered the charac- teristics three types iron and the effect various heat treatments the microstruc- ture and hardness each material; data the flame hardening unalloyed, chro- mium-nickel, and chromium- molybdenum cast iron the method; and standardized operating con- ditions for the hardening flat surfaces. Herein, experi- mental data are presented faces. Herein, experimental data are presented the hardening steel parts the progressive method. ° just below the transition zone. The photomicrograph F-315-A shows the structure approximately 0.005 in. into the transition zone. should noted that the amount ferrite very ap- preciably reduced this zone. How- ever, this can more readily observed the photomicrograph F-339 the same zone. This second photomicro- graph was taken after the specimen bring out the hard constituents which are starting form and cannot clearly distinguished from ferrite par- ticles reproduced print. may observed from the hardness data hardness has increased from 28, shown for the base metal, range into the transition zone the acicular structure becomes more definite and the ferrite particles are smaller and more scattered. The scleroscope hard- ness this depth 63. Photo- micrograph F-317 shows the definite acicular type structure produced depth 0.040 in. may observed from the photomicrographs taken depth 0.060 in. and the surface the flame hardened specimen, that fine acicular structure continues throughout the hardened zone. or- der make direct comparison be- tween the furnace hardened structure and the flame hardened structure, small cube the same steel used for this test was hardened oil quenched according recommended practices. The structure produced shown the photomicrograph F-340. may clearly observed that the flame hardened structures are equally good not superior those pro- duced furnace hardening. Although the data, shown the | | | curve Fig. 20, was developed for SAE 4145 steel, the photomicrograph shown Fig. illustrate that the re- sults produced when 3140 steel hardened accordance with the same data are entirely satisfactory. should noted from these photo- micrographs and the hardness data tabulated Table that the transi- tion zone broad, ranging from 0.020 in. 0.030 in. 0.035 in. felt that this broad transition zone ab- solutely essential flame hardened parts are used where excessive shock and fatigue conditions prevail. Although the base metal shown the series structures considered pearlitic, equally good transition zone obtained the steel has pre- viously been heat treated and drawn back Brinell hardness 269 321. course, this treatment would produce sorbitic base which would gradually transform the martensite the case hard surface. may noted from Fig. that the dis- tance between the work surface and the tip the torch 7/16 in. for the steel part rather than the in. used for cast iron parts. Extensive experimental work that there tendency for the steel sur- face overheat when these operating conditions are employed. However, has also been found practical crease this distance 15/32 in. without appreciably affecting the depth hard case produced. All the steels used for flame ened parts should purchased closely controlled metallurgical speci- fications. example two such specifications are shown. Purchasing Specification No. Forgings Grade: SAE number 4145 standard analysis acceptable. However, carbon con- tent 0.42 0.48 more desirable. Grain Size: This steel have grain size checked the McQuaid-Ehn test. Grain Structure: This steel furnished with lamellar pearlitic structure. Heat Treatment: This steel normalized tem- perature above the upper critical and cooled the proper rate produce the desired grain structure and hard- ness. Hardness: This steel must within the Brinell hardness range 187 217, with desired hardness 207. Purchasing Specifications No. Forgings Grade: SAE 4145 standard analysis ac- ceptable. However, carbon content 0.42 0.48 more desirable. Grain Size: This steel have grain size checked the test. Heat Treatment: This material shall properly nor- malized and heat treated the re- quired hardness. This steel must within the Brinell hardness range 269 302. for other grades steel can made. Although much more elaborate speci- fications could drawn for large consumers, those shown here have proved entirely satisfactory. Type No.! Pressure Lb. per Acetylene All the steels flame hardened grained classified the McQuaid- Ehn test. However, other investiga- tions have reported that this factor has very little any effect the re- sults obtained. Quenching Medium well known fact that SAE 3140 and SAE 4145 steel are general- quenched oil the furnace meth- heating employed. However, per cent soluble oil quench- ing solution has been found entirely satisfactory for spray quenching both grades small sections, that where the surface being hardened not more than in. wide. Heavier sections SAE 4145 steel are generally quenched with water spray. Although culties have not been encountered with the quenching mediums mentioned, maximum hardness not absolutely essential soluble oil solution may Water /eve/ Single flat surface Torch 4380 Mixer Airco Tip Airco with holes Lineal travel in. per min. > + + Distance tip above Water Width Surface Hardened and No.of Flames Applied IG. 20—Satisfactory operating pressure produce 3/32 in. 5/32 in. hard case SAE 4145 steel. This curve applies flat surfaces the same basic de- sign that illustrated. The hardening carried out under the conditions shown. THE IRON AGE, November 1940—55 { 3 : e Torch tip 4 | | | 9 > + + + . + + + + { | > +> + —> + - - + + + > + 4 + > + + } + + + + + + 4 + + + SS. q q 4 | + + + + + + employed for all sizes surfaces and the concentration may slightly in- creased desired. This will, course, reduce the hazard sur- face checks. Although the type soluble oil used for the quenching medium may not major importance, Socony Vac- uum Hob-o-Sol has been used for all tests herewith considered. sul- phurized type that was designed pri- marily for gear hobbing. The solu- tion much more oily nature than some the other types and leaves oily film the parts, thus elim- inating rust and should clearly understood that there may other types soluble oil which will give equally good results. extensive experiments hardening steel parts other than flat surfaces have not been considered this series investigations, unques- tionably accurate could prepared for flame harden- ing parts which have designs similar those shown Figs. and 12. (See issue Oct. 31.) example large part regu- larly flame hardened production basis shown Figs. and 24. These parts are made SAE 4145 steel. They range size from 14% long. They are hardened four sides and must free from soft corners soft streaks. These results are ob- tained grouping torches shown Fig. and hardening entire surface one pass. may ob- served, the water level within in. the surface hardened. This essential conduct the heat away from the outer corners sufficient rate prevent hardening the ad- jacent faces. may noted that the two end tips are equipped with ad- justable deflectors. These have been found absolutely essential pre- vent the hot gasses from causing ex- cessive turbulence the water. This turbulence has two detrimental effects. The first that will blow the water away from the point where the heat being applied and will permit corner hardening. The second disadvantage that the water will interfere with the burner action and frequently blank out extinguish the flames. The two wide sides the bar are first hardened and then the two nar- row sides are hardened. The set for hardening the narrow sides identical that shown Fig. with the exception that the water level raised within 1/16 in. the sur- face hardened. This precaution absolutely essential prevent the 56—THE IRON AGE, November 1940 DISTANCE FROM BASE STEEL DISTANCE FROM BASE STEEL ened faces. With these practices care- fully followed there danger either cracking the corners pro- ducing soft spots streaks. The parts shown Fig. have average sample part 12% in. wide was hard- ened and broken. This part showed uniform penetration hardness in. Although there was very slight decrease the depth hard- ness the point where the tips were separated, this was very small mag- nitude and there was decrease the surface hardness. These bars were formerly made SAE 2315 steel, carburized ened. This process necessitated machining operations, eight which can eliminated when the flame hardening process used. The operations which can elim- inated are herewith listed tabular form: (1) Renormalize after rough machining. (2) Sand blast. (3) Finish plane. (4) Carburize after semi-finish machining. (5) Sand blast after carburizing. *(6) Straighten after carburizing. (7) Sand blast after hardening. *(8) Straighten after hardening. *The particular bars which are iillus- trated Figs. and not require the straightening operation. However, there are many very similar bars lighter proportions which straightened, and the operation will discussed the following brief analysis specimen SAE 4145 ste lated Fig. 20. 500 dia 060 SURFACE Bars the type shown Figs. and must necessarily purchased with rather large amount stock allow for the machining operation. The heavy cuts required remove this stock set appreciable machin- ing strains which must eliminated occur the carburizing and harden- ing operations. view the very great difficulty straightening bars this type, was found necessary relieve these strains when they were processed the carburizing method. However, possible eliminate this operation when the ening process employed. That is, three major operations can taken from the production schedule, namely F240) FURNACE HARDENED hardened accordance with the data tabu- meters; per cent nital etch. normalizing, sand blasting planing. course, the finish planing cut required when the bars are proc- essed the flame hardening method, but this