The Iron Age 1941-03-06: Vol 147 Iss 10

COMPANY DELAWARE CLAYMONT, MARCH 1941 a of, d 4 : MORE PRODUCTION with this NEW WARNER SWASEY SLIDE TOOL OLD TURRET LATHE Ona grooving operation aluminum fan housing, produc- tion was stepped 20%. The diagrams show how this new slide tool handles boring, recessing, grooving, facing, inside facing, back facing operations. The feed lever can set any position. One complete turn the handle moves the cutter two inches. Adjustable stops and micrometer dial govern slide travel and assure accuracy cuts. This slide tool, which handles operations never before combined one tool, only one 596 improved tools that can help you produce more from your present turret lathes. Write You CAN TuRN BETTER. FASTER. FOR LESS WITH WARNER SWASEY TOOLS Deep Hole Facing. When end bore reached, the operating lever moves the Angular Stub Boring Bar, and deep hole face cut squarely and Recessing. Here Straight Cutter Stub Boring Bar re- cesses inside groove. The graduated dial stop screw can set hold and repeat accurate Straight Cutter Stub Bor- ing Bar back faces the piece. Boring and Outside Grooving. When the boring cutter finishes the inside cut, the slide lowered and the Straight Stub Boring Bar Cutter forms the outside groove. Straddle Facing. Two ters simultaneously face both sides the | LZ Y | x = 9 \ 08) =: | \\ — 1 § ASE Z ere Bor- piece. ooving. cutter ut, the Bar utside MARCH 1941 VOL. 147 NO. VAN DEVENTER President and BAUR Vice-President and General Manager Managing Editor News Editor Technical Editor Machine Tool Associate Editor Editor WINTERS Art Editor Washington Editors MOFFETT JAMES ELLIS Resident District 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 Ontario St. Louis LEROY ALLISON Newark, Editorial Public Misinformation Technical Articles Armored Steel Aluminum Castings for Aircraft Lessons Arc Welding ...... Coolants for Cutting Steel Industrial Lighting Equipment ....................... Features News and Market Reports News Machine Tool Activity ...... 126 Non-Ferrous Market ........ 127 113 Scrap Market and Prices ... 128 January Pig Iron Output 114 Fabricated Steel ........... 130 Metal Working Activity ..... 115 Reinforcing Bars ......... Comparison Prices ...... 116 Iron and Steel Prices ...... 132 Summary the Week ..... 117 Pig Iron Prices. The Industrial Pace 118 Warehouse Prices .......... District Market Reports 120 Sales Possibilities Products Advertised Index Advertisers Copyright, 1941, Chilton Company DIX, Manager Reader Service Advertising Staff Robert Blair Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Chicago Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Don Harner, Pacific Avenue, Long Beach, Cal. Emerson Findley 621 Union Cleveland Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts index. Pub- lished every Thursday. Subscription Price: United States and Possessions, Mexico, Cuba, Canada, $8.50; Foreign, $12.00 year. Single copy, cents. Owned and Published CHILTON COMPANY (Incorporated) Publication Editorial and Office Executive Offices Chestnut and 100 East U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE 4 hen the the Bar, cut ‘ately, 158 raight re- hold a | face piece. | j 4 ‘ i é } MAHON Can Make Matter How Complicated Engineered ACCURACY that insures certainty fit. Clean cut, smooth APPEARANCE that cuts down machining and finishing costs. Rugged STRENGTH which welding effectively provides. These outstanding advantages are yours when you specify Machine Bases and Frames made MAHON. Years specialized experience producing un- usual and complicated designs have created background reliability and resourcefulness, which many foremost man- ufacturers have come rely upon the elimination after troubles and expense. THE MAHON COMPANY | | \ | q ; = j 2 ‘ MARCH 1941 ESTABLISHED 1855 Public Misinformation HEN man elevated his fellow men position power and influence, the public expects him set example both for knowledge and probity. Thus, when makes important statement the press audience, should sure his facts and should present them without twisting distortion. Such man Philip Murray, president the CIO and head the steel workers’ union. Mr. Murray ought know the steel industry. The public would assume that does from his recent offer join the Government and the heads that industry the management its affairs. Atlantic City Feb. 25, Mr. Murray addressed the 12,000 people attending the 7lst annual convention the American Association School Administrators. Charging that the Army and Navy had discriminated placing defense contracts favor few large corporations, Mr. Murray, widely reported the press, said that one steel company was produc- ing per cent the nation’s armor plate and building per cent the nation’s merchant marine. speaking armor plate, Mr. Murray was speaking armor plate for ships. This thick plate produced pressing and not rolling the lighter armor plate used for aircraft, tanks and armored cars. the four producers this country who have the enormous fur- naces and presses capable turning out this thick plate and heat treat- ing it, one company has capacity more than per cent the total. Thus, any one the four had per cent the armor plate business, the other three would have but per cent and would operating only per cent their capacity. This course ridiculous the face it. were true would indictment the intelligence; not being true reflects Mr. knowledge credibility. Take your choice. His statement that this same company also producing per cent our merchant vessels equally misleading and untrue. recent list- ing all merchant marine vessels order under construction pre- pared the authority “Marine Engineering” and published January shows that the company having the largest merchant ship tonnage order has but per cent the total. Merchant vessels now under construction this country for the Gov- ernment well for private accounts aggregate 1,952,452 tons. this total the largest single backlog 675,500 tons. Our Naval authorities and the OPM are playing favorites. They place orders where there the ability and the capacity produce the goods with without the union label. Stretching the truth 200 per cent may permissible when telling fish story your friends. not excusable when top flight labor leader addresses the American public. | 2 | | A 7 & Inland Watches the That Help Make Quality Stee important reason why true value each pound Inland Steel the close attention every detail Inland steelmaking. Proof watchfulness over things” found throughout the Inland plants, and all service departments. Take for example, tests the Inland open hearth furnaces. Repeated tests are made the molten bath and slag from each furnace determine the progress the refining action each heat. Analyses are made for carbon, manganese, phosphorus and sulphur the steel, and ferrous oxide the slag. Each analysis SHEETS STRIP STRUCTURALS TIN PLATE PILING RAILS BARS accurately determined within minutes from the time sample taken. Not single detail furnace operation and product control omitted refining Inland Quality Steel. There are scores other examples Inland atten- tion details—from careful selection raw materials proper loading the finished product for safe transit and fast unloading. The Inland custom doing “big things” well, and giving close attention “little things” your assur- ance high quality steel and cooperative service. PLATES TRACK ACCESSORIES FLOOR PLATES REINFORCING BARS | } . Dearborn Offices: Milwaukee, Detroit, St. Paul, City, Cincinnati, New = —Today, composite steels have come age. Thou- sands tons are service and the future bright in- deed. Fabrication fre- quently easier, costs are lower, and the possibility great saving strategic materials particular importance war creeps ever closer. back the dim reaches time, some un- known but very skilled Sec- ond Dynasty Egyptian metalworker hammered out ewer. His work- manship was quite meticulous— perhaps had lot time his hands, what with wife away all day over the brew- ery helping out with batch beer. What really puts the ewer class itself, however, that the oldest known example plated metal. There’s thin smear silver over the copper body, and evidence points crude hot ham- mer forging the two metals prior fabrication the vessel. Such plating operations became increasingly familiar the thou- sands years passed. Sometimes the plating was decorative in- tent; sometimes complete deception intended—as, instance, 4000 years later when the Egypt- ian government used each year “wow” the natives Mecca sending “Holy woven gold thread. But, the gold thread was plated silver; bars silver were wrapped round sheets gold and hot hammered together, then passed through series draw plates. Then, the first shift from plated non-ferrous metals completely utilitarian plated ferrous metal occurred some hundreds years later, the fif- teenth century, when Bohemian ironworkers the Erzgebirge mountains introduced tin plate. ARMORE LIPPERT Technical Editor, The Age Really great strides plated materials only got off good start within recent years, how- ever. Everyone today familiar electroplated metals, used either for decoration for pro- tection. But, electroplating both slow and expensive, and has only been within recent years that some other method joining ferrous metals progressed much beyond the hot hammering operation the THE IRON AGE, March 1941—35 - a = 4 Second Dynasty Egyptian metal- worker. Innumerable attempts have been made get firm bond between ferrous metals, and all these major efforts have been correlated into note this page. The newest such methods, and one about which very little known, facing operation developed Hopkins the plant the Kellogg Co., Jersey City. After many test runs that plant, the Allegheny Ludlum Steel Corp. be- came interested, and August, 1939, asked that machine designed for them. This was done, and the first heat made the ma- chine around the end 1939, was utensil throughout the land. The process and product are frequently called Pluramelt, although late the facing carbon steel with stainless alloys referred armoring steel against the ra- vages corrosion, heat and wear. Any new industrial practice, like the three-hooped pot, bonded into practical unit virtue three equally important components: (1) Production technique. (2) Product characteristics. (3) Product applicability. Quite naturally the latter major laic concern—for, after all, consumer acceptance the one component which can neither slurred nor romanticized. None the less, the production technique and and their examination permits more sensible evaluation the en- tire process. The spate Pluramelt publicity year ago was directed establish- ing the premise that the union be- tween stainless facing and carbon steel was like the affaire “indissoluble.” Other than demonstrating satisfac- tory performance every physical test that human ingenuity could devise prove the permanency this bond (see THE IRON AGE, Feb. 1940, and page herein), noth- ing else has been forthcoming from Brackenridge. This has been conscious and deliberate policy. Only few company officials and workmen have been the locked commercial grade and today seeing service many kitchen more than characteristics the product are building housing the Pluramelt equipment. The industry Composite Metal—70 Years Inventive Persistence: The only reliable record the constant attacks the ex- asperatingly difficult procedure facing ferrous metal with some other ferrous non-ferrous metal bundled the dusty files the Patent Office. The crackle old patents could well the susurrant scratching inventors’ heads— heads harassed with the necessity securing perfect union the two metals. Literally hundreds inventors have made pass composite metals. There has been much chaff and some kernels new ideas. The kernels are about follows: The union dissimilar metals casting casting and working (forge welding) one the oldest the present methods and probably the first find its way into U.S, patent. Thus, 1868, patent No. 73,375 was issued J.Park, Jr., for method for, ‘‘combining copper and cast steel, casting the molten steel around the copper, which previously heated, thus forming ingot which may hammered, rolled, otherwise worked into any desired 1869 Absterdam (No. 97,582) set down idea for the manufacture composite steel which was made Bes- semer steel base and cementation steel coating. And, 1872, Meneely (No. 126,894) described process somewhat like that Parks but wherein the iron steel base metal was preheated and the coating metal, brass, bronze, gun-metal other copper alloy was poured. The same general method was proposed little later for the manufacture armor plate composed base steel one hardness united depth steel different hardness (Nos. 188,458 1877 and 239,155 1881). From the last date and into the 1900’s considerable number patents were issued this same general method producing composite articles wide range analysis. Then, Davis 1909 (No. 935,358) disclosed the first radical departure from prior practice. Davis proposed pro- duce armor plate fusing depth the base plate means closely spaced electric arcs and incorporating nickel, chromium, carbon, etc., into the molten metal produce depth metal integral with the base but having different analysis and hard- ness. likely that this patent what might termed patent,” far known the new method was not used successfully produce any plate. Berg then presented further departure from the prior prac- tice (No. 936,514 also issued 1909). Therein, Mr. Berg con- templated the manufacture copper copper alloy clad steel and proposed covering the surface the steel base metal with flux prevent oxidation high temperature, laying the copper copper alloy cladding material the fluxed surface, passing electric current through the adjoining surfaces generate, resistance, heat sufficient commingle the two metals and unite them, then, after the composite has cooled, rolling desired gage. Simpson 1913 (No. 1,064,671) added the method Davis (No. 935,358) the idea carrying the operation out vacuum. Here again the patent likely ‘‘paper patent”’ its contribution would seem render the successful operation the method even more doubtful. Next came Brown, who 1915 (No. 1,127,177) disclosed the surfacing rails with wear resisting manganese steel means the electric arc. Brown had several proposals, (1) place the rail strip manganese steel and fuse the rail means carbon arc, (2) fuse manganese electrode and the surface metal the rail produce deposit man- ganese steel, and (3) fuse mixture manganese oxide, aluminum and iron steel filings with surface metal the rail carbon arc produce the manganese alloy situ. The present author has been unable find out whether this proposal ever went into use. Heuser 1916 (No. 1,196,544) proposed clad one metal with layer another metal fusing the cladding metal the base metal means the carbon arc. was about this time that chromium alloys appeared the industrial scene, and would logically expected there immediately appeared attempts use them coating material the cladding steel. All these efforts can within approximate limits broken down into the following three categories: (1) Producing the composite welding sweating plate, sheet, alloy similar body base metal by, (a) Work, forge, welding. (b) casting molten base metal against solid plate, sheet the alloy and then hot working the result- ing ingot complete the union the metals and obtain the composite the desired shape and size. ae (2) Producing the composite uniting sheet plate the alloy the final thickness plate sheet the base metal, also the final thickness, welding one the other arc, gas spot resistance welding. (3) Producing the composite operations which all the alloy deposited fused condition solid base metal. The composite may worked, but the working not depended upon produce the union. This class may subdivided into, (a) When the alloy such fused and united, and (b) When the alloy produced situ during the fusion and welding operation. Under (a) may listed the following patents: Gillespie 1,306,690 (1919) Gordon 2,133,291 Kelley 1,365,499 (1921) Gordon 2,133,292 (1938) Johnson 1,886,615 (1932) Gordon Maskrey Gordon 2,133,294 (1938) Armstrong 1,997,538 (1935) Ostendorf 2,199,321 (1940) 36—THE IRON AGE, March ! | | H | — H j | | whole knows little the process other than the sketchy details set forth the various Hopkins pat- ents. And, like all masterpieces the patent attorney’s art, the dis- closures therein resemble British igencies are covered, but infor- mation given the enemy. Production Technique Now, regards the production technique; the process unique, cleverly conceived expertly worked out. may well one the seminal developments mod- ern steel technology. might expected, the carbon steel usually comes the Pluramelt However, ingots have been used di- rectly numerous instances. Slab ingot, the surface sometimes blasted, although surface preparation frequently ignored. frame fastened around the slab, the assembly picked crane and lowered into the Plura- melt machine. Therein, dogs are tightened clamp the assembly into such position that about 2-in. space left between the slab surface and the mold wall the machine. Into this 2-in. space lowered the working head the Pluramelt machine. This head though simple design, actually the physical evidence many years ventive effort the part Mr. Hopkins and several hundreds thousands dollars Kellogg money. the saying goes, “the works,” and being works” quite understandably rather closely guarded secret. The work- ing head carried framework which runs vertically guides the superstructure the Pluramelt movement, this superstructure quite lofty. Feeding mechanisms for the raw materials are located various sections the here that unique steel making practice evidenced, practice in- volving continuous feeding steel constituents down through the working head. The feeding equipment made number metering machines, all controllable from central operat- Johnson 2,059,584 (1936) Huston 2,225,868 (1940) 2,064,684 (1936) should interest note that even Gillespie, who was the first this field, considered his contribution new article manufacture rather than new method—he discloses more than the then known methods producing clad ma- terials. obvious from these patents that difficulty was experienced bonding chromium-containing alloys carbon steel the hot working method. Thus, the first Johnson patent directed facilitating this bonding by, (1) the removal air between the metals, (2) the provision intermediate sheet pure iron which will fuse more readily the alloy and the base than these will each other. Armstrong follows the lines Johnson but proposes thoroughly clean the surfaces united and electroplate one both them deposit that Armstrong also proposes addition the electro-deposition nickel silver prevent carbon migration from the steel base the alloy during the hot working. Gordon his four patents proposes the use what may termed brazing com- pound (manganese and mixtures manganese and one nickel, cobalt, chromium and iron) between the surfaces united assure their union. Huston proposes nickel sheet between the alloy and the steel base. Under (b) may listed the following patents: Armstrong 1,757,790 (1930) Ingersoll 1,983,760 (1934) Ingersoll 1,868,749 (1932) Harvard 2,056,673 (1936) Ingersoll 1,963,745 (1934) Ingersoll (1937) Ingersoll 1,967,754 (1934) Armstrong 2,074,352 (1937) The patent Armstrong discloses the general method and points the main problems. The main problem, course, secure union between the metals throughout their interface: and, another important problem prevent undue fusion the alloy while assuring fusion between the metals. Ingersoll his patents proposes various solutions for these problems. Under (2) may listed the following patents: Andrus 1,680,276 (1928) electric resistance spot welds alloy base metal. Johnson 1,690,684 (1928) fusion welds alloy base metal along continuous lines. Johnson 1,824,898 (1931) plug welds unite alloy base. Andrus 1,840,305 (1932) like prior Andrus patent but unites with base and alloy the flat, then rolls shape. Swearingen 1,920,534 (1933) unites alloy base welding slots alloy. 2,015,173 (1935) like prior Andrus patents but lining itself composite alloy and steel base. Moses 2,164,074 (1939) plug welds composite lining steel base. Andrus Trainer 2,214,002 (1940) spot welds alloy throughout interface; uses nickel sheet between alloy and base prevent carbon migra- tion into alloy. Under (a) may listed the following patents: 1,709,729 (1929) covers inside outside, both iron pot with overlapping beads chromium-iron-nickel alloy. Fifield 1,864,590 (1932) forms coating flowing stellite thereon. Duff 1,883,630 (1932) alloy face steel vessel. Under (b) may listed the following patents: Case 1,909,252 (1933) 2,191,475; 2,174,175; 2,151,915; Meier 2,091,871 2,191,476; 2,191,477; 2,191,478; Kinkead 2,175,606 (1939) 2,191,479; 2,191,480; 2,191,481; Kinkead 2,175,607 (1939) Hopkins Nos.: (1938-40) 2,107,943; 2,151,914; 2,151,915; 2,191,470; 2,191,471; Andrus 2,219,352(1940) Armstrong forms alloy heads valve stems fusing metal the stem metal the electrode and added metal together. Case and Meier are along the same lines. The Kinkead patents disclose method somewhat similar those Davis and Simpson although probably superior reason the improved apparatus available the later date. Kinkead preheats the base metal and like Simpson progresses the base under the elec- trodes whereat the fused base metal intermingles with the alloy constituents form the desired alloy coating. Andrus discloses method wherein preformed liner sheet placed the metal base fused thereto along separated lines spots means the submerged arc and electrode sufficient alloy content compensate for dilution the base. The welding takes place through the liner. There are also other patented proposals which have not been classed above. these, No. 2,046,638 (1936) discloses the packing the steel base with ferrochrome and and heating 1700-1900 deg. F., whereby chromium absorbed the steel base form chromium alloy coating the steel. Hudson (Nos. and discloses continuous methods for producing clad strip composed steel base with alloy coating each side. Due the difficulties experienced pro- ducing steel strip continuously similar methods the practical value these disclosures doubtful. The Mudge patents (Nos. 2,037,732 and disclose methods for producing nickel-clad steel. Between 1930 and 1940, Chace disclosed methods for producing copper copper alloy clad steels. (Nos. 1,755,425; 2,125,153; 2,156,331; 2,169,354; 2,174,733; 2,190,310; 2,193,246; 2,195,613; 2,195,614; 2,199,150; 2,211,922; These methods generally include casting and rolling. THE IRON AGE, March 1941—37 : : ] ) | ’ | | | e | — 38—THE IRON AGE March LEFT Frequent verify alloy quality. ° ° ° BELOW slag band checked operator. LEFT head ap- proaches end run. ing panel, each meter being con- nected with hopper containing particular raw material. One hop- per, for instance, may contain pow- ferrochromium; another, powdered ferrosilicon; another, fer- romanganese; another ferrocolum- bium; another, ferrophosphorus, etc. Practically never iron pow- der fed into the working head. The iron constituent for the alloy facing made part from the carried into the system the fer- roalloys, and part from picked from the melted portion the exposed face the carbon steel slab. There .practically limit regards the complexity alloy constituents that metered into the system one time, although great skill ob- viously required determining metering rates, each the fer- roalloys carry fractions various elements into the system, the car- bon steel contributes fractions elements, and each ferro- alloy has different rate re- covery (although all Slag constituents are fed hand, required, into the space between the slab face and the mold wall. | | | i Electrical energy required also varies with the alloy being made, the size slab being armored, and the speed operation. With everything set and controll- able from central panel, the ma- chine started. The operation complex system synchronized movements with very little personal supervision required. The working head slowly works from the bottom the slab upward, with alloying elements constantly feeding the bath underneath the slag. Note that far more than simple fusing op- eration with the slab face takes place—a substantial depth the slab actually melted off form part the bath. This second (or dual) melting part the carbon steel the basis for the name the process—Pluramelt. Indicative the precise opera- tion the machine the necessity ° ° ° Armored ingot removed from machine. Numbers indi- cate points analysis: 0.062 19.0 Cr, 9.0 Ni; 0.058 19.1 Cr, 9.1 Ni; 0.060 19.0 Cr, 9.0 Ni; 0.060 18.6 Cr, 8.8 Ni; 0.062 18.5 Cr, 8.6 Ni; 0.062 18.8 Cr, 8.9 0.060 c. 18.7 Cr, 8.8 Ni; 8 = 0.059 18.6 Cr, 8.9 Ni; 0.061 Cr, 8.9 Ni; 0.062 18.6 Cr, 8.6 Ni; 0.060 18.8 Ni. ° ° ° gradually changing the pace upward movement the working head offset the gradually rising temperature the slab face and mold space. The working the equipment not bit spectacular. There are electrical discharges pyrotechnics, and noise—in fact, possible stand the platform around the mold chamber and unable tell whether not the machine operation. From this description, ob- vious that the Pluramelt process essentially precision electric furnace, completely mobile within certain prescribed limits, continuously fed with exact pre- determined quantities raw ma- terials which melt form alloy steel under carefully controlled refining and protective slag. That the metering raw materials precisely the rate desired as- sured frequent metal samples dipped from underneath the slag, shown the color photo page 38. These samples are given quick tests which may result some minor adjustment metering rates; they then the labora- tory for complete analysis record the full history each armored slab. Slag also occasionally tested and perhaps altered slightly the test dictates. This con- stant checking during the opera- tion assures the best possible alloy quality. During the writer’s inspection the Pluramelt machine, carbon slabs in. wide in. thick ft. high were being armored with 18-8 stainless steel stabilized with columbium. The machine was mak- ing alloy facing rate more than ton per hr., which cer- tainly respectable pace for such tons have been faced such manner, and fact there size limit. However, combination finishing mill loads Brackenridge and consumer demands have re- the slab size previously mentioned. The two other color photos page show the working head approaching the top the slab. Easily visible the wide band hot slag along the slab face. the working head moves upward there results progressive feeding and freezing the alloy metal, and when the machine turned off the end the run, and the metal cools, there found prac- tically negligible piping and segre- gation. Obviously, therefore, hot top loss not factor this process. Carbon steel can faced with practically any ferrous alloy, and commercial composites are being made each week varying from very low straight-chromium armoring nickel-chromium alloys with various trick additive ele- ments. More than one side the slab can faced, course, merely working another face during second run. Product Characteristics much for the production tech- nique. Next, what about the char- acteristics the product? The question immediately begs for answer. Since much the carbon steel slab face melted off, the expectation might logically that the band interfacial al- loys between the carbon steel and outer layer alloy steel would quite broad. But such not the case. The photomicrograph shown all Pluramelt ingots after they are broken down into plate sheet form and heat treated. The photomicrograph 100 THE IRON AGE, March 1941—39 r- j e | 1). diameters, and includes the junc- tion carbon steel base metal and type 304 alloy Pluramelt plate. The section was previously heat treated air cooling from 1950 deg. Etching the pol- ished sample was carried out elec- trolytically per cent oxalic acid. The austenitic grains the alloy portion are clearly outlinea and carbides are solution, was determined examination higher magnifications. The aus- tenitic alloy, course, typical type However, note the dark band approximately 0.0005 in. wide the junction the alloy and carbon steels. thought some that this band carbides, but other ,authorities believe this effect traceable polishing. the band does contain carbides, they have observable effect fabricating properties the com- posite. Furthermore, Pluramelt al- loys containing such band have been service high tempera- tures for many thousands hours without any evidence change. Recently type 410 CARBON STEEL Junction 100 diameters. Dark band 0.0005 in. wide, and may contain carbides. There migration carbon into alloy portion after thousands hours high temperature service. TABLE Pluramelt was examined after 11,- 000 hr. service 830 deg. There was widening the dark Physical Properties Carbon Steel Armored With Various Types Stainless band, neither was there migration Alloys. (Also, comparative data for carbon and alloy steels alone.) Alloy Strength—, Elongation measured in. all thicknesses over all thicknesses in. and under. 40—THE IRON AGE, March 1941 carbon into the alloy portion. Point The next question that might Type Test Lb. Per Sq. In. Lb. Per Sq. In. Per Cent arise would concerned with No. Bar* Bend major segregation uniformity, 304 67,420 40,420 40,460 29.3 30.6 being prompted the fact that alloying ingredients are being 57,480 56,320 32,910 31,240 35.8 35.6 constantly into the bath. Ina 52,290 52,200 31,870 31,130 32.0 31.0 year’s commercial operation there 82,160 81,170 40,420 41,150 57.0 60.0 have several a7 9 29 atta 56,700 29,450 31,020 39.2 33.0 batches, traceable human errors 316 58,960 61,420 33,200 34,100 42.0 18.0 these few exceptions, the armored 53,500 54,740 32,140 34,770 28.4 27.6 ingots have had test samples bored 51.2 out from all over the surface and 90,640 92.940 43,830 630 thin demarcation line, the result 347 64,830 65,380 47,000 30.7 28.7 always being uniformity anal- ‘6 S 48,400 50,060 34 34,480 35.0 3 4 0 ( VK on page 39 shows an ingot just 61,220 60,660 40,5: 39,340 25.2 25.5 armoring machine; and, shown Ss 50 3° 38,55 31.0 32.5 . “4,04 6, 9,20 ov.é J 58,770 59,000 36,400 28.1 26.3 number points where test bor- 54,500 56,250 32,500 29.2 28.4 ings were made for analysis, the 69,350 67,890 41,000 38,400 29.5 30.7 results being indicated the cap- ion. fact, even greater num- 68,430 70,200 42,900 51,050 24.0 23.5 were used, 54,520 55,760 30,690 2,550 34.7 28.0 show them all 49,500 49,170 27,820 8,200 39.0 39.0 mess the photograph. 61,520 71,240 40,310 0,770 23.0 21.2 The evidence metal quality coming from the microscopist and the chemist would indicate that physical and corrosion performance wee a> i j 2 - / : A | | — would However, complete judgment the armored steel requires complete testing. satisfactory. Table shows the physical prop- erties variety Pluramelt Reduced Tensile Alioy Type No. Bar, Lb. Per Sq. In. types, comparative data being pre- 304 64,000 sented for the composite, the car- 70,500 bon steel alone and the alloy facing alone. general, the properties the composite fall somewhere between those the carbon steel 347 73,000 and the alloy steel, which about 70,000 what might expected and cer- tainly satisfactory from technical standpoint. stitched seam welded with ease, 59,650 arc welded with deterioration 446 the joint certain technique followed. The sheet edges welded are separated distance 57,900 TABLE Physical Properties Arc Welded Plate Armored With Various Alloys Elongation, Per Cent Free Bend, Alloy Inside Reverse Bend, Alloy Outside 32.4 50.0 28.6 35.6 33.2 36.0 6.0 32.0 3.3 32.2 31.8 33.5 37.0 35.0 32.7 31.6 30.0 44.0 39.6 39.5 32.7 $3.0 39.4 34.0 37.0 33.0 32.0 34.2 32.0 33.1 31.7 TABLE Strauss Test Alloy Portion Pluramelt Plates equal the total thickness the Test After Hr. Boiling metal. jig should used, which Heat Alloy Per Cent Per Cent the two edges, which also act 304 chill plates. Full penetration 347 18-8 fissures achieved with one bead, and the 347 18-8 fissures bead laid from the armor side. igher alloy rod employed than 316 18-8 slight fissures the alloy armor, overcome any 316 18-8 fissures danger dilution the alloy weld 1850 deg. air cooled; 1600 deg. air cooled; 1600 1150 metal the steel back; for in- F., S.R.; 1850 1150 deg. F., S.R. stance, the armor stabilized 18-8, 25-20 coated rod would gether the seam, which will re- recommended. stitch welding sult completely fused joint. employed, the fabrication carried welds made the manner out have alloy faces to- described have physical properties Examples how steel double armored with 18-8 can deep drawn and spun without intermediate annealing. Spun separator disk steam table insert (left), Bain- Marie cooking unit (middle), and sample deep drawing (right). wa comparable with those shown Table II; these data more than meet the minimum requirements set forth A.S.M.E. and codes for unfired welded pressure vessels, and believed that ar- mored steel will soon given the green light for this type appli- cation. The performance the armored steel the accelerated tests de- termine corrosion resistance also quite satisfactory. Although single test can completely evaluate the resistance stainless corro- sion, the results the Strauss and Huey tests would quite indica- tive. Table III shows the results the conventional Strauss test (cop- per sulphate, sulphuric acid) the alloy portion the armored plate, determine the susceptibility the alloy intergranular corro- sion. The performance quite ade- quate; the type 316 shows some small fissures one test, which not surprising inasmuch molybdenum not complete sta- bilizer. The Huey tests, the results which are shown Table IV, probably the most important stand- ard examination corrosion re- sistance that can made. This test, first applied Huey THE IRON AGE, March ER 4 i J ‘ ? a duPont exam- ine steels for nitric acid lows penetration 0.002 in. per month for stabilized 18-8 steel. The data Table show the Plurament alloy easily meeting this specification. Fabrication Performance Other corrosion tests are pos- sible, for instance penetration orthophosphoric acid. This acid very severe stainless and frequently encountered the chemical and refinery industries. The author has seen the results such tests, some which actually show the Pluramelt alloy perform- ing better than commercial solid stainless steel. Inventor Hopkins blushes with pride such data, but not inclined insist that Pluramelt alloy actually superior solid commercial alloys. Even though the physical prop- erties the armored steel are creditable, some question might still arise fabricating per- formance. was found that the Pluramelt sheets, partic- ularly the double armored mate- rial, could subjected much more severe cold working with- out annealing than could solid material comparable gage. This demonstrated the illustration page 41, showing some very deep drawings and one spinning, each which demanded intermediate an- nealing. Such performance most welcome fab- ricators; probably the soft steel core acts some- the work hardening the alloy facing. Another illustration the deep drawing prowess double armored steel shown the photo page 44, this particular steel being ar- mored with 18-8. The utensil in. diameter and in. deep, and was fabricated three draws with anneals between draws. The maker stated that the same utensil made solid stainless re- quired four draws with anneal between the second and third draw. Very important also the uni- formity the stainless armor after drawing and polishing, shown the same photo. wide strip was cut from one edge the other, and placed boiling nitric acid dissolve all mild steel; mea- surements were then taken in. intervals shown—note that the protective coating remains uni- form after drawing. This performance armored steel the draw press has been considerable help number manufacturers, speeding op- erations larger draws without any increase press power size. Probably the largest draw currently being made armored steel the wash bowl the Bradley wash fountain, in. diameter and in. deep. The press available that plant was not powerful enough form such bowl out solid stainless metal the gage desired, but Pluramelt was Severe test bond quality. 2-in. square plate armored 18-8 one side, with hole reamed clean. picture shows test from start alloy ductile and there separation. « 4 4 out any intermediate annealing. Other applications numerable types cooking uten- sils, for which service the armored steel has the added advantage higher heat conductivity because the mild steel core. Many drums and barrels for food chemicals and paints are now being made this armored steel, and plates are finding wide application oil refineries. Large tonnages are going into cans for printers’ inks, and, course, there wide use for work table tops, sinks, etc. Because lack capac- ity, strip applications are yet completely unexplored, this very large tonnage commodity the future. New Steel Making Technique Mr. Hopkins’ energies over the past year have been addressed primarily killing off few minor production bugs fabrication characteristics the rolled armored (single double) steel. all times, however, cosseting the idea that this produc- tion technique has possibilities far beyond the armoring carbon steels with various grades stainless al- loys broken TABLE Boiling Per Cent HNO; (Huey) Tests Alloy Portion Pluramelt Inches Penetration Per Month Alloy Heat Alloy First Second Fourth Fifth Type Treatment* Composition Hr. Hr. Hr. Hr. Hr. 304 18-8S 0.00075 0.00055 0.00064 0.00052 0.00052 304 18-8S 0.00093 0.00077 0.00116 0.00120 0.00157 310 l 25-20 0.00043 0.00045 0.00076 0.00108 0.00128 316 18-8 0.00079 0.00073 0.00074 0.00080 0.00099 347 1 18-8 Cb 0.00051 0.00034 0.00029 0.00028 0.00029 347 18-8 0.00052 0.00046 0.00054 347 3 18-8 Cb 0.00062 0.00065 0.00087 0.00107 0.00144 1850 deg. F., air cooled; 1600 deg. F., air 1600 deg. 1150 deg. F., S.R. down into plates The one-year commercial opera- tion the Brackenridge machine has satisfactorily demonstrated the efficiency this unit for simple facing operations. Many hundreds tons the single double ar- mored steel are now kitchen fix- tures, utensils and general food handling processing equip- ment, oil refining chemical equipment, tank drums, etc. Most likely tough steels will armored with variety very hard steels, the two being rolled down into resisting light armor plate with formances should such promise variety applications Army equipment and air- craft. much for what has been done commercially. regards carbon strip, armored with stainless tool steels, exploitation this highly attractive outlet has yet even been attempted, mostly because rolling facilities Allegheny Ludlum are for the time being over- loaded. Certainly interest, however, ‘are explorations with improvised the Kellogg plant Jersey City. For instance, number round billets with stainless outside with stain- less core (or both) compounded. Such billets have per- formed most encouragingly tube and bar mills and wire dies. The diversity such products and their applications are limited only the ingenuity design engi- neers—tubing lined inside out (or both) wire bars with uni- form and coating, the thickness the skin controllable from smear for fenc- ing appreciable amount cope with the rigors chemical operations, oil and dye processing, clever specialties, for in- stance high steel with wedge-shape facing stainless, rolled into knife blades that the blade surface stainless and the ground cutting edge exposes the tool steel; any number types and shapes tough carbon steels faced with tool steels, rolled and formed into inexpensive, easily worked and very serviceable cut- ting, forming and punching dies, etc. All these more-or-less experi- mental forays are just about what might expected view the dual (or plural) melting and refin- ing characteristics the Hopkins process. Each such products can offer wide range physical and corrosion resistant properties neers designing consumer goods, capital goods and military equip- ment. And, the potential savings strategic materials thus made possible assume particular impor- tance these days possible shortages almost every direction and the likelihood increasing stringency the parlous times ahead. But within recent months far more dramatic role has been en- visaged for the Hopkins process 4 > | than the scribed herein. the quantities test data were digested, the re- alization grew that this process facing operations de- conceivably primary producer steel—the alloy steels are controllable within very narrow limits and are very high and uniform quality; furthermore, ingot piping and crop losses almost approach the negligible. Why then not use the process OUTSIDE INSIDE ARMOR TOTAL ARMOR 0.0055 0.0284 0.0048 0.0059 0.0286 0.0054 0.0064 0.0293 0.0052 00062 0.0297 0.0298 0.0284 0.0287 0.0292 0.0288 0.0275 turn out solid billets stainless and tool steels, and all those other types specialty alloys high intrinsic value, made small lots, and subject multitude con- trol difficulties refining and high crop losses. That this vista quite intriguing there denying, and already few hesi- tant experimental steps have been made such direction. Admit- tedly, not all the steps have been huge successes, but the proportion encouraging results has been such demand in- vestigation. Hopkins’ set-up melting and feeding (of raw ma- terials) units can operated water-cooled copper mold, re- fractory mold—the shape either may round, square, rectangular, what shape size considered most efficient for subsequent roll- ing forging operations. The re- sulting steel billet slab has prac- 44—THE IRON AGE, March 0.0048 0.0276 0.0056 tically pipe, therefore, yields are the order per cent. Anal- yses are very uniform. And, while the molten metal the Hopkins machine far has been found cost fraction more than molten metal conventional practice, the yield high and the product far along the path finished article, that final costs can quite conceivably run favor the Hopkins metal. 2 o ° ° ° Just recently the first test run special steels was carried out the instigation indepen- dent tool steel producer. The pro- ducer dished mean task—he requested four steels the fol- lowing analyses: Cc 1.45 - 1.60 0.90 -0.95 0.95 -1.04 0.95 -1.10 0.35 0.40 1.50 -1.60 0.15 -0.30 0.20 -0.40 0.20 0.40 0.10 -0.25 0.15 -0.30 0.10 -0.35 max. 0.020 max. 0.015 max. 0.025 max. 0.025 max. 0.020 max. 0.015 max. 0.025 max. 0.0267 0.0050 0.0053 Based past experience with stainless alloys, calculations were carried out determine the meter- ing raw materials into the mold for each the four steels, e., how much powdered ferromanga- nese, ferrosilicon, ferrochrome, ferrovanadium, ferromolybdenum, ferrophosphorus, sulphur, iron and slag constituents were fed into the work chamber each minute, each constituent course draws in. diameter,/ deep) with anneal. Fig- ures indicate thickness inner and out- armor and steel core being adjusted take into account the Fe, and traces other elements carried into the mold, and also the recovery each alloying element (which very high). The metering dials were set, the syn- chronizing speeds (which vary for the different steels) mated and set, and the power re- quirements were calculated. Every- thing was then turned on, and the machine went its quiet way build square billet. The output commercial machines this type could stepped employing specially designed battery units. The table (next page) what results were obtained for each the four steels. The analyses (1), (2), (3), (4) were made center, outside, top and bottom the ingot, and for some the shows 0.0060 0.0293 0.0055 ° grades only analyses critical elements were carried out. {1 1.52 0.97 0.99 0.73 )2 1.48 0.94 0.99 0.72 Cc \3 1.49 U.98 0.99 0.64 1.47 0.98 0.99 0.64 1.66 }2 1.63 {4 0.42 1.66 0.23 0.17 9 4 0.31 0.11 0.20 0.66 4.23 2 4.29 4.20 4 1.18 1 11.70 . 2 11.63 4 11.74 La 0.04 0.58 {1 4 1 0.81 0.33 0.7% 0.33 0.81 0.32 14 0.80 0.33 0.014 0.012 1 {4 0.016 0.020 0.04 For the most part, these results are surprisingly good, thanks the process and the skill calcu- lating the input raw materials. should noted that the chemical analyses are quite consistent and close specified ranges, except for Grade 47. This particular alloy ob- tained its tungsten from granu- lated tungsten ore, and the calcu- lation quantity metered each minute was based loss sili- con for reduction. However, what actually occurred was preferen- tial loss carbon, the result being that silicon high and carbon far too low the finished steel. subsequent heat, with tungsten ore and ferrosilicon recalculated, came very close specification—the re- covery tungsten very high and use ore has effect the cleanliness the steel. heat, made with ferrotungsten, has worked out even better. None the less, must pointed out that all three heats have shown consid- erable variation tungsten the billet. The belief is, however, that this difficulty with tungsten can easily ironed out additional heats are made. But, all things considered, difficult deny that these trials were surprisingly good for first runs. Each ingot the four tool an- alyses hot worked beautifully, with cracks. Extensive tests showed the steel most respects equal similar steels made conventional methods. Grade has consistently been the best, although Grades and have been very promising. Ingot grinding losses were not se- vere, and the finished bar recovery has been the neighborhood per cent, compared with recovery about per cent for the best regular manufacturing practice. These tests and few others made within the past several weeks may prove nothing regards the future metallurgical and competi- tive status the Hopkins machine primary producer alloy bil- lets. Results date, however, are far more encouraging than first runs new processes usually are. fair appraisal will require least another year experimenta- tion, and after that interval re- examination the machine will order. Every day this continuously fed, accurately controlled, flexible and mobile “electric furnace” demon- strating its ability turn out high-grade, versatile and competi- tive commercial product that constantly exploring new and un- expected consumer outlets. (Car- bon steel faced one side with for substantially less than solid stainless; double armored steel currently sells for about the same price solid stainless.) There ever the possibility that the process may parlay its way into the highly com- petitive, highly arcane production field solid stainless, tool and spe- cial steels. Industry has this equipment radically different and tantalizing production tool meet the ever more difficult and ever- changing demands large indus- tries and casual consumers. Mr. Hopkins, who isn’t steel man and therefore not subject the multi- tude do’s and dont’s and better- not’s prevalent the industry, has waded where most steel men have hesitated tread. has presented the steel industry with adolescent which may well ma- ture into adult capable de- manding respectful recognition the elder techniques the open hearth, the electric furnace, and the bessemer converter. THE IRON AGE, March 1941—45 | | J 4 , 4 - is | 5 » = q F | | —Continuation series lessons enable beginners master the fundamentals bare and shielded-arc welding techniques. ESSON No. Object weld together two in. using single bevel butt joint. Apparatus used Flex Arc weld- ing machine, chisel, hammer and wire scratch brush. Material used two in. thick plates, in. wide and in. long, one which con- tains deg. bevel along one end, and 5/32 in. diameter Flex Arc welding electrodes. Fic. plate for single bevel butt joint. 46—THE IRON AGE, March INSTRUCTIONS: butt joint joint design such type that all welding may done from one side the plates and only one plate beveled, shown Fig. 21. Such design presents greater welding problems than the single vee type because not wide and because one side the joint right angles the plate surfaces. has the advantage, Normal fillet Convex fillet metal fill the joint.. Because the narrow included-angle the joint important that the root the joint spaced in. (See Fig. Three layers are required fill and reinforce single bevel joint between in. plates. string bead should used deposit the first layer and weaving proce- dure deposit the other layers. (See Fig. 21b.) PROCEDURE: Set the polarity re- versing switch straight polarity, adjust the welding current 150 amp. and clamp the plates welded flat the welding table, being sure space the joint in. shown Fig. 19a. clamps are not available, tack weld the plates together each end the joint. Weld the plates together us- ing three passes, previously dis- cussed. Carefully clean all spatter, scale and oxide from each layer be- fore the next one deposited. careful obtain complete fusion all times. Inspect each pass for uni- formity appearance and try improve the appearance the weld progresses. After the joint completed have the instructor inspect for appear- inspection make nicked groove the top layer near the vertical fu- sion zone the joint, discussed Lesson No. and fracture the specimen. The exposed fracture should sh