The Iron Age 1941-05-15: Vol 147 Iss 20

Timken ROLL NECK BEARINGS Are The lubrication TIMKEN Roll Neck Bearings not affected higher mill speeds. You get positive, unfailing lubrica- tion with the same smooth, steady bearing performance any and every mill speed—from the lowest the highest. Tapered TIMKEN BEARING EQUIPPED And when the mill stopped for roll change some other routine purpose, there bearings; delay re-starting; damage the bearings themselves through lack lubricant any point. These advantages are basic roller bearing advantages. You need and should have them new and existing strip, sheet plate mills—hot cold. Specify TIMKEN Roll Neck Bearings—the roll neck bearings with phenomenal tonnage rolled rec- ords combined with low bearing cost per ton. THE TIMKEN ROLLER BEARING COMPANY, CANTON, OHIO TAPERED ROLLER Manufacturers TIMKEN Tapered Roller Bearings for automobiles, motor Listen the cranes your plant. Grinding and screech- ing are unfailing signs excessive wear crane—and that means expensive maintenance and repairs. Whiting cranes run smoothly and quietly. They have roller bearings, tapered-tread drive wheels, flexible couplings, oil-flushed load brake, rotating-axle bearings, and many other special features. That’s why Whiting cranes give you extra years service. Capacities from 400 tons. electric hoists from tons. Whiting Corporation, 15601 Lathrop Ave., Harvey, Builders quality cranes for over years. SEND FOR BOOKLET “How Write Traveling Crane Specification.” OVERHEAD Herringbone Gears Reduce Noise and Wear WHITING CRANES Herringbone gears trans- mit power quietly and efficiently through con- tinuous rolling contact. The precision-cut gears outlast ordinary spur gearing least TRAVELING CRANES Also MAY 15, 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 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 Teronto, Ontario St. Louis LEROY ALLISON Editorial Technical Articles Pig Iron and Ingot Mines Priorities and the Ultrasonics—A New Metallurgical Tool ...... Heat-Treating Machine Tool Report American Gear Association New Equipment Features the Assembly Line the West Coast Fatigue Cracks News and Market Reports News Industry Machine Tool Activity 109 Non-Ferrous Market 121 Comparison Prices Construction Steel Summary the Week 113 Iron and Steel Prices District Market 116 Sales Possibilities QO O Products Advertised Index Advertisers Copyright, 1941, Chilton Company DIX, Manager Reader Service Advertising Staff Herman, Chilton Bldg., Philadelphia Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Don Harner, 1595 Pacific Avenue, Long Beach, Cal. Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts index. Pub- lished every Price: United States and Possessions, Mexico, Cuba, $6.00; Foreign, $12.00 year. Single copy, cents. Owned and Published CHILTON COMPANY (Incorporated) Publication Editorial and Office Executive Offices Chestnut and 100 East 42nd Pa. New York, U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President GEORGE GRIFFITHS, President EVERIT Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Lilt — ARE DESIGNED, BUILT AND TESTED Hundreds installations widely diversified industries have proved the outstanding ad- vantages Westinghouse Gearmotors for slow speed drives. Gearmotors costs and reduce maintenance expense because belts, pulleys. sprockets are required. The exact output speed can obtained simply installing one unit. And with West- inghouse Gearmotor, low output speed pro- vided with the full efficiency high speed drive—efficiency ranging from 94% 98%. The design and construction Westinghouse Gearmotors make possible solve many slow speed drive problems economically. West- inghouse Gearmotors are built one complete unit. The result balanced drive which all parts are matched provide maximum 36—THE IRON AGE, May UNITS results. Smooth, quiet operating gears are assured because Westinghouse makes its own gears—gears that are accurately cut from forged steel and heat-treated the exclusive Westinghouse BPT process. Built one complete unit with all parts accurately balanced and matched, Westing- house Gearmotor will deliver its full torque under load and withstand the shocks even the most severe service conditions. Gearmotors are available all standard motor ratings and wide variety special enclosures. Your Westinghouse representative will glad give you complete details. WESTINGHOUSE ELECTRIC MFG. CO. EAST PITTSBURGH, PA. sere ; ‘ | MAY 15, 1941 ESTABLISHED 1855 Pig Iron and Ingot Mines spirit fun pervades most occupations America, fortunately, beginner apprentice. remember quite vividly, although was some years ago, being sent through the aisles railroad shop get left handed monkey wrench for the mechanic whose helper had just become. Later on, the publishing business, participated with others selling shares pig iron mine cub advertising salesman who was devoid industrial information that probably thought that shoes grew shoe trees. That learned fast, however, evidenced the fact that this man now owns and runs some very successful publications. Many word spoken jest turns out have actually been spoken earnest, although its speaker was totally unaware it. And there may more this pig iron mine business than appears the surface. Also steel ingot mines. Suppose right now, for example, could dig down into the earth and bring pigs iron and ingots steel instead having through the process mining ore and coal for smelting and melting. What help that would be, particularly, after coal strike and when the industry being pushed for every last ton production. mentioned this thought, jocular way, steel man recently and was surprised find that took seriously. said he, “you've got something there.” “Government,” continued, “has for years been buying the productive surplus farm products and storing them, awaiting the day come when could sell them below cost give them away. And Government has been buying the world’s surplus gold premium and burying Fort Knox. Government had only done that with pig iron and steel ingots, what nice position would Silly, not? But perhaps not silly seems. Government purchase surpluses can have but two sound objec- tives. One, the farm surplus matter, ameliorate the impact under demand and over supply upon the producer and his labor. The other provide for emergency which demand may exceed capacity produce. Neither these, course, applies the gold buy and bury plan. takes long time turn gold into tanks projectiles airplane engines through the route purchase and production and even gold won't when you get iron steel with. our Government had kept our steel mills running purchasing their potential surpluses ingots per cent production rate during the years ended 1940, would now have some 404 million tons steel buried underground ready dig and put immediate use. that something. 4 é 4 i } New York REINFORCING BARS Chic * treet, les Offices St. Kansas City, arborn STRUCTURALS BF « feo 4 x g ‘ \ } / 4 a j i FLOOR PLATES \ 4 q ADOLPH BREGMAN Consulting Engineer, New York word “priority” now industrialist alike. appears every other page the public and trade pa- pers. But few outside the in- dustry itself know its bearing —and its life death meaning— electroplating. shortage several the ma- terials used electroplating has already been reported. Part this shortage doubtless due users, but obvious that real stringency here, today. The de- gree which electroplaters are concerned best illustrated the fact that the liquidation plant Philadelphia March, 3000 nickel anodes were sold auction for $2.10 (against standard value 48c.). nickel being held for $1.50 condition which recently called forth severe criticism from an. the Plater —Or, what when anodes and plating salts become scarce. Leon Henderson, Director Price Stabilization for the Defense Com- mission. this writing nickel anodes are subject priorities and nickel salts are becoming scarce. Cad- mium anodes and cadmium oxide are both scarce. chromic acid looms. relatively easy obtain, but the Rochelle salts used copper plat- ing are already scarce. There shortage zinc metal, but not yet shortage zine salts. Tin metal, since there domestic supply, sure become scarce sooner later, but the salts, upon which tin electroplating depends, are obtained locally from the stripping tin plate, and reasonably plentiful. Naturally the time this article appears print these situations may change; accordingly the must once con- sider the several substitutes and expedients that may soon become imperative. The expedients possible include the following: (1) the use scrap metal anodes; (2) the use insoluble anodes while the solution fed from salts; (3) the substi- tution other metals, either wholly part. Nickel Probably the most important single type plate nickel, tonnage metal consumed, dollar value and effectiveness part the product, for the following rea- sons: (1) cannot sold without decorative protective finish, both. (2) most cases the decorative finish must protective well, since most plating done steel which must protected against rusting. (3) the combination tective nickel the most important single element. Few, any, commercial decorative plates handed, effective rust preventives. They are almost always applied over substantial coating nickel which provides the protection re- quired. (4) large volume industrial metal products, machine parts, chemical equipment, etc., call for THE IRON AGE, May —_ ° ° ° ° } | heavy coat nickel for resistance corrosion and physical wear. Nickel also used increas- ing extent for building worn and mis-machined parts. (5) Nickel plating therefore indispensable part huge volume consumer and industrial metal products. The present stringency nickel was caused primarily the de- mands the Defense Program for steel armor plate, haps secondarily over-purchas- ing the part some commercial users. According some opinion, this shortage may only tem- porary, and the supply the long run, may sufficient take care all normal demands, including those the Defense Program. But even this optimism justified, the careful electroplater will use all possible methods conserva- tion, and will study tute suitable his line. 40—THE IRON AGE, May — The materials used standard nickel plating include high purity cast nickel anodes, “depolarized” (containing traces nickel oxide) which may either cast rolled. The bath contains nickel sulphate, boric acid which serves buffer, and some- times other salts such as_ nickel chloride ammonium chloride. The nickel very often deposited over undercoat copper. Scrap Anodes this writing, metallic nickel the form anodes, either cast rolled depolarized, hard obtain. The first comes mind, and the one that ABOVE ORROSION rolled de- polarized nickel anode (99+ per cent) nickel electrotype solution. From Nickel Solutions and Anodes, George Hogaboom; Technical Bulletin No. International Association Electrotypers and Stereo- typers, issued Feb. 28, 1941. Courtesy Hanson-Van Winkle- Munning Co. LEFT EPOLARIZED nickel anodes, 99+ per cent. Courtesy Hanson Van Winkle Munning Co. filter bag keep impurities from the so- lution and conserve metal. Courtesy Van Winkle-Munning Co. involves the least alteration shop routine use scrap metal instead the usual anode. Scrap nickel, the form anode stumps and spines, strip, clippings, tons left after stamping operations, the like, packed into non- metallic basket, close contact with small anode. Rubber, porce- ‘an used but care must taken keep bits metal from dropping out they decrease size. The process goes much usual, except that greater care must exercised comparable quality obtained. Thus, there may occasional poor con- tacts; the metal serving anode likely become coated over; this accompanied porosity the maintaining proper contact also causes current losses crease the costs operation. Insoluble Anodes The second the expedients mentioned above the use in- soluble anodes and increased quan- tities nickel salts. The deposit just the same usual, but the | operation calls for considerably more care and expense. One plater has estimated that while nickel the anode costs 46c. per the nickel fed rinses are recommended, well other precautions avoid un- necessary drag-out and chemicals. Carbon, graphite other anodes, insoluble the acid nickel bath, may employed. Carbon anodes are made gas carbon, bonded with tar the like, then baked. They tend disintegrate under usage, especially the presence sulphates, and must therefore, watched. Silver-lead' anodes have also been suggested, and another third type anode copper- silicon lead-iron-tin alloy—its trade might employed nickel plat- ing well. must remembered chlorides will attack any metal anode—even platinum anode—dissolving and releasing chlorine gas. Accordingly when working with any the metallic anodes mentioned above, the plater must sure that his bath con- tains chlorides. Lead (even chemical lead) for example, would quickly into solution and then deposit out with the nickel give rough, dark, spongy deposits. that (In electrolytic analyses, when chlorides are present, custom add some toluene the solution inhibit the attack the liberated chlorine the anode, which usually platinum. The effect this material the nickel yet been investigated.) When working anodes, course necessary feed the solution often with nickel sulphate and the same time dispose the accumulation sulphuric acid that builds the bath. This best done adding barium hydroxide, which the same time takes out the sul- and neutralizes the acid: Ba (OH) + H.SO, BaSO, 2H.O The barium sulphate precipitates extremely fine white powder which must removed filter- ing through close-textured paper Tainton, Patent Nos, 1,759,- 493 and 1,851,219, Metal Finishing, April, 1941, 181. —an operation that difficult perform even with good equipment. Calcium carbonate can used in- stead the barium hydroxide, but the resulting calcium sulphate noticeably soluble. The carbon di- oxide gas that forms during the reaction, some which remains warming the solution, brittle nickel deposits result. The changes the solution can minimized proper buffer- ing. Boric acid generally em- ployed for that purpose, but others may more effective pH’s under and between and 6.5, according Satisfactory buffering permits the use higher current densities and consequently, faster plating. Among the buffers sug- gested for pH’s below are acetic, formic, citric hydrofluoric acids and their salts. The nickel sulphate used elec- troplating domestic origin, being obtained by-product the electro-refining crude cop- per. The nickel that contaminates eps native copper ore collects the solutions used copper refining, and crystallized there, then puri- fied and sold. Since the country expects the domestic supply cop- that the supply domestic nickel sulphate will adequate. (At present not easy obtain, perhaps because over-purchasing because the sudden increase its use). Nickel chloride gen- ABOVE UBBER coated "anode scrap saver" bas- ket. Courtesy Automotive Rubber Co. LEFT CRAP showing method use. Courtesy Belke Mfg. Co. erally obtained by-product the electrolytic deskinning high- purity nickel anodes; consequently time when nickel anodes are not being made, this salt will correspondingly scarce. Nickel carbonate available, better than calcium carbonate for addition nickel sulphate bath, builds the nickel supply, while the same time the car- bonate ion neutralizes the excess acid. One recommended method making such additions fol- lows: remove about gal. the THE IRON AGE, May 15, ' | solution from the tank; heat this 50-gal. lot boiling and add 1/3 oz. per gal. Make the addi- tion very slowly. Adjust the 6.8 and return the gal. the tank through filter cloth. Substituting Other Metals Nickel plate good quality is, has already been stated often deposited undercoat cop- per. The relative thickness these two deposits can varied; thus, nickel hard get, thicker copper underplate and thinner nickel top coat can used without sacrifice corrosion protection. The thinner nickel plate wear through shorter time heav- ier chrome will counteract this wear great extent) but when permanent good looks are not primary consideration, this expedi- ent one the first occur. However, involves little extra expense operation, and somewhat more troublesome buff the heavier copper underplate. Another word caution order: buffing the nickel deposit avoid waste com- modity. Buffing can applied the basic metal and the copper undercoat; then the nickel should deposited bright, simply touched up. Silver Substitute for Nickel nickel and certain the other base metals truth become scarce unobtainable for non-defense items, the manufac- turer metal products may well metal, and may shock some read- ers see mentioned here this connection. However, much cheaper than used be—35c. per oz., and one the few metals which the U.S.A. has over- supply. There already huge sup- plies vaults over the country, and (since silver by-product the refining copper, lead and gold, all which are being mined accelerated pace) the domes- tic supply likely increase, rather than decrease. The use silver instead nickel would add something the cost each article—a cost that many cases will willingly borne the consumer. For deposit 0.0002 in. brass—the cost metal Edited Lawrence Addicks, Director the Silver Producers Research Project; the chapters coatings Addicks, 42—THE IRON AGE, May 15, would about per sq. ft. for nickel and per sq. ft. for sil- ver. Silver beautiful, and has strong sales appeal. tarnishes readily, but such formations can delayed the use clear lac- quer. Silver solutions are easy handle and the old solutions can easily treated for the recovery waste metal. Within recent months most in- formative volume, entitled Silver has come out with Uncle benediction. The book contains the work some contributors, tions carried out the Silver Pro- ducers’ Research Project, whose purpose was stimulate interest the many industrial possibilities silver. immediate interest view the uncertanty nickel and tin supplies the information the use silver lining for containers. Several methods applying sil- ver coatings are discussed detail, including methods electroplating silver form that remarkably free porosity. The use silver plate containers for food, bever- ages, cosmetics, pharmaceutical products and the like, encour- aged, since silver has tericidal powers. This suggests that its use kitchenware the cheaper kind, much which now nickel tin plated, might well attempted the latter metals prove unobtainable. glance the many small articles sold the 5c. and 10c. stores, many them already silver plated and many others quite suitable for that finish, should prove the reader that silver plate may promising answer pres- ent problems. Copper stringency metallic copper for use anodes has already ap- peared. Copper sulphate and cop- per cyanide are this writing available, but certain other salts, notably Rochelle salts and sodium cyanide used making the alka- line copper bath, are already scarce. There reason believe however, that since copper domestic origin, there should perma- nent shortage. There are two main types copper solutions—the acid copper bath and the alkaline copper bath. The preferred anode both proce- dures rolled annealed copper. the case nickel, the use scrap copper for anodes suggest- when full-sized copper anodes are not obtainable. Also, the case nickel, possible, though not convenient, work with in- soluble anode (Chilex, for example acid sulphate solution and steel for alkaline solutions) and feed the bath wholly from salts. This plan requires the exercise close control over the composi- tion the bath. Thus the case the acid bath, the acidity the solution increases the metal con- tent decreases and necessary overcome this effect the addi- tion copper oxide copper bonate, passing the spent solution over fine copper filings the presence oxygen. the case the cyanide bath, the metal content decreases the content increases and the same time carbonate formation, The cyanide content quite crit- ical, high values the efficiency drops very low figure. For example the optimum free cyanide content Rochelle copper solution about oz. per gal. sodium draws 100 amp., about 6.7 oz. copper will deposited per hour per cent efficiency. This will liberate 13.8 oz. sodium cyanide 0.14 oz. per gal. the end the day, allowing for losses de- composition the free cyanide will more than doubled. excess cyanide not simple. Addition copper car- bonate results the liberation the very poisonous cyanogen gas and accumulation carbonate which must eventually removed. holding high tempera- ture will decompose the cyanide but this procedure too, Eventually will necessary discard the solution unless refrig- erating plant installed crystal- lize out excess carbonates low temperatures. Cadmium Cadmium plating carried alkaline bath made from sodium cyanide and cadmium oxide —and anodes cadmium metal. the present writing there great shortage cadmium metal and cadmium oxide well the cyanide. How long this condition will remain difficult foresee, but immediate improvement not sight cadmium only by- product production. Cadmium plating can carried out successfully with insoluble anode—steel, for example—if cad- mium oxide, cadmium hydroxide cadmium cyanide added prop- quantity. Fairly close control necessary the ratio cadmium cyanide must maintained. Even cadmium anode metal available, there tendency for sodium carbonate accumulate, and when insoluble anode used, this tendency more pronounced. The carbonate ‘comes from two sources: part the result the decomposition the cyanide ion into carbonate and ammonia, and part picked from the carbon dioxide the air. The decomposition cyanide goes all times, being hastened heat. The acquisition carbon dioxide from the air especially pronounced when working with insoluble anode because this opera- tion accompanied spattering and spraying the solution due liberation oxygen gas the anode, the spray coming contact with the carbon dioxide the air and carrying back into the solu- tion carbonate. This building carbonate concentration noticeable all alkaline solutions. The excess car- bonate may removed part chilling the solution about deg. F., which temperature the excess sodium carbonate crystallizes and can filtered out. Another way add specially prepared gypsum (U. patent No. 2,164,- 924) throw down calcium bonate, then filter. The latter method has the disadvantage causing accumulation sodium sulphate the bath. Plating There this time shortage zinc metal, due more lack Patents Nos. 1,435,875; 1,451,543; 1,497,265; 1,064,307. Steel, Jan. 1941, Plating Direct from the Ore By-Products Will De- refining capacity than any shortage the source. Zinc salts useful the plater are still rea- sonably plentiful. scrap, zinc, clippings, etc. are available, the first expedient used the plater could the substitution scrap metal for anodes, packing around small metallic anode described above the section nickel plating. plating carried out two types baths—the alkaline zinc cyanide bath, and the acid sulphate bath. Normal procedure ABOVE EFT ROLLED copper disk anode Patent No. 1,373,693); right—cast copper quoit anode (U. patent No. 693). Courtesy Han- son-Van Winkle- Munning Co. RIGHT OPPER disk anode and lead spine for acid cop- per solution. Cour- tesy Hanson Van Winkle-Munning Co. calls for anodes zine zine alloys containing mercury, alumi- num, magnesium and calcium’. the case other metals, possible work with insoluble anode and feed the bath adding the zinc salts. With the alkaline bath there the same accumulation carbonates noted above; there considerable spraying the anode, and carbon dioxide from the air captured and converted into carbonate, which can removed the addition gypsum. steel anode could used with the alka- line bath, and zinc oxide zine could used feed it. With the acid bath, lead-silver anode preferred, when zinc cess acid tends accumulate, and this can reduced the addition zine carbonate zinc oxide, which the same time builds the zinc content. All these alternative methods are more expensive than the con- ventional practice. Yerger points out that rapid progress being made plating zine from solutions pre- pared leaching waste, taining materials such salam- moniac skimmings and other prod- ucts the hot galvanizing indus- try, well from the This would obviously conserve metal and reduce the load the produc- ing capacity the country, well effecting savings the plating operation. Tin The electrodeposition tin generally carried out with pure tin anodes, alkaline bath which sodium stannate the main con- THE IRON AGE, May 15, > f : ; —— 4 ; i d 4 —— 4 | . | stituent. Since there are domes- tic tin sources, obvious that the present shortage tin metal should not expected loosen the near future. the salts, sodium stannate made locally, being obtained stripping tin from tin plate. possible, fact easy, work with insoluble (steel) anode, feeding the bath with sodium stannate. The usual accumulation carbonate takes place, but before, removed chilling the addition gyp- sum. The caustic soda content also increases and regulated addi- tions acetic acid. Tin also electrodeposited from acid solution, tin sulphate being the principal care must taken control the accumulation acid, which done adding stannous oxide inter- vals, the same time building the tin content. Tin usually classed with the base metals, but far from cheap. not surprising, therefore, that silver frequently suggested substitute for tin plate, particularly connection with articles used with foods, beverages, pharmaceu- ticals, and cosmetics. Tin and sil- ver have much the same appear- ance, and the shortage tin, with the almost inevitable price rise, should expected, there good reason suggest that huge stores silver this country may advantageously drawn upon. Yerger, the article al- ready mentioned, advocates the use electrolytic tin instead the hot-dipped tin because the plated deposits are third the weight the hot-tin de- posits. Also there the possibility plating tin strip one side only for certain tin can applications placing sheets back back, thus effecting even further savings. Chromium Chromium important con- stituent certain steel alloys ne- cessary defense. not sur- prising, therefore, that the supply chromic acid should already have become restricted. The practice chromium plating use in- soluble lead anode, and bath whose main constituent chromic acid. Accordingly, the expedients suitable for are not available here. other words, the supply chromic acid fails, the plater will simply have stop chromium plating. Perhaps will utilize some other ver, tin (if can get it) perhaps some copper brass finishes that were vogue before chromium plating was perfected. Economic Aspects Although manufacturers plated products would greatly inconvenienced, the great- est sufferers from complete stop- page plating supplies would have been the contract platers. The contract jobbing electro- plating industry service in- dustry exclusively. The platers take metal products parts made their customers, apply finish spe- cified the customer and return the parts. this fashion, they not only serve those manufacturers who have metal finishing depart- ments their own, but they also take care the surplus over- flow from manufacturers who have The OLD wasteful method of ANODING The NEW EFFICIENT GRAPHIC representation the advantages ball anodes over the slab type. Courtesy the Udylite Corp. 44—THE IRON AGE, May 15, LEFT ALL anode and anode holder. Courtesy Hanson- Van Winkle-Munning Co. RIGHT ARBON anode for nickel so- lution. Courtesy Hanson- Winkle-Munning Co. plating plants, but are unable take care their own output the peak seasons. The total value work done contract platers may estimated $20,000,000 $25,000,000 per year. (See Census Manufactures, 1939. Electroplating, Plating and Polishing.) The number men employed this industry about 10,000. These figures are small, however, comparison with the importance the industry key operation the manufacture metal products. Exact statistics are not available, but has been estimated that the contract electro- plating industry directly indi- rectly affects many times these fig- ures value manufactured metal products. Tight is, this time, the writer has been authoritatively in- formed that the nickel anode situa- | tion may improve. one time seemed though the supply nickel for plating would cut off, but the present time, this does not seem necessary. (On the other hand, well-informed factor the industry believes that June, nickel salts will considerably freer for all plating purposes, but that nickel anodes will hard get for some time come.). this time fantastically high prices for nickel salts are being though the regular distributors salts without interruption, the same schedule prices both for original packages and for less than original packages, that have been effect for number years. now said the intention Washington allocate enough nickel plating keep operat- ‘Acknowledgment made the author, of assistance in the preparation of his article, from Hoke and Nathaniel Hall. ing, provided this can done with about half its former requirements. Platers who can get along with few hundred pounds per year may hope obtain enough keep them running they can operate less nickel than formerly. view the small amount metal involved, per cent cut the small users may sufficient, although the hope that ways may found for them use even less than per cent ments run into tonnage must re- duce their consumption much greater amounts keep the whole field within the necessary limita- tions. These allowances will, course, cramp the plating industry certain extent, but obviously better than the original prospect metal all. The industry will not have shut down, but will find ways and means, its own ingenuity, turning out its work even though the supply nickel restricted. Those dealing with this situation the Office Production Man- agement are practical men with experience making production job go. They are working hard fair all concerned and they know that manufacturers, ware- houses, and platers must work to- gether order keep this in- dustry its feet while the De- fense Program goes forward with the necessary speed. Conclusion Shortage alone need methods can found; but costs will higher, and the con- sumer 1941 must satisfied with thinner plates; possibly with finishes quite different from what they have been Meanwhile panic buying and hoarding should not nanced. the Defense Program really requires the metals, the elec- troplater will with less, but will still manage serve his customer given only half chance. Production Chromium-Molybdenum-Aluminum Steel METHOD producing chrom- ium molybdenum aluminum steel basic electric furnaces util- izing the works’ own scrap contain- ing 0.35 0.42 1.4 Cr, 0.3 0.5 and 1.0 Al, was described Goldman Stal, 1940, No. the Iron and (British). Preliminary which the scrap was first melted acid electric furnace and then mixed with charge basic elec- tric furnace, proved unsuccessful. the method developed, the scrap was mixed with per cent low- carbon iron mild steel and melted down basic electric furnace, lime being added. fluid slag comprising 1.5 2.0 per cent the melt was formed oxidation the constituents the charge and some attack the refrac- tory lining; this slag contained per cent, magnesia per cent, alumina per cent, ferrous oxide 1.5 per cent, manganous oxide per cent and chromic oxide per cent. The composition the metal after melting was: Carbon 0.30 0.40 per cent, manganese 0.20 0.35 per cent, chromium 0.80 1.10 per cent, molybdenum 0.25 0.40 per cent, aluminum 0.15 0.30 per cent and silicon 0.05 0.25 per cent. The slag was removed, but little was left protect the metal, and deoxidation was affected adding either coke or, better still, charcoal and lime mixed with small amounts ferrosilicon. The refining slags contained lime per cent, magnesia per cent, alumina per cent, fer- rous oxide 0.3 1.2 per cent, man- ganous oxide 0.12 0.42 per cent, and chromic oxide 0.8 per cent. The alumina content favored rapid deoxidation the refining slag. The necessary amounts ferro- chromium were added the begirning the refining period. was tapped into ladle which the required amount aluminum had been added. The results the examination the microstructure and me- chanical tests are discussed; these results were very uniform and some cases the steel obtained from charges which included the works own scrap was superior that ob- tained from charges with scrap, and satisfied the technical speci- fications. mental heats was shown that the self-forming slag (i.e., slag formed without the addition fluxing agents) could used for refining and deoxidizing purposes. elimi- nating the need for forming sec- ond refining slag, the time for re- melting was shortened hr., per cent. conclusion, the results mi- croscopical examinations the cast and the rolled steel are dis- cussed. The number non-metallic inclusions the steel refined under second slag was about the same that refined under self- forming slag, but sulphide inclu- sions predominated the latter. the rolled steel the distribution and shape the non-metallic in- clusions caused less ferrite band- ing the steel produced with works scrap the charge than that for which scrap was used. THE IRON AGE, May | Superfinish Improved MORE exact control the various specific factors that determine quality surface finish, mechanically produced, has marked recent production surface smoothness. This has included the adoption controllable and draulic pressure abrasive stones place spring pressure posi- Mid-West abrasive superfinish stone 500 600 grit Rockwell c4 cio «(C25 Brinell no. 202 223 255 Brinelldia 465 440 425 405 46—THE IRON AGE, May 285 tive cam pressure, studies effects varying the pressures during the operation, especially the final stages, and studies the path pattern which the abrasive elements should take the surface pro- duce optimum results. Attention has been focused the tempera- tures produced the surface the abrasive; also, C35 C40 C45 C50 C55 C60 375 429 495 555 627 682 360 3.35 315 295 275 260 245 2.35 Hardness conversion table steel finished FOR accurate selection Superfinish stones, Midwest Abrasive Co., Detroit, has developed number system ratiag abrasive stones that permits the selection the basis the known hardness steel finished. The steel hard- ness, either Rockwell Brinell, indicated the base the chart. The arrow indicates the number the stone recom- mended for Superfinish. speed abrasive grits the metal surface has been called important. Stone grading means hard- ness tests has become widely ac- cepted since its publication “Testing Bond Hardness Abra- sives” (THE IRON AGE, April 25, 1940). Developments the direction assuring constant bond characteris- tics the abrasive elements and increasing production Superfin- ished parts are claimed now Midwest Abrasive Co., Detroit. practice, some stones, sup- posedly identical, have been found vary tremendously grain structure and cutting qualities, even though superficial examina- tion and hardness tests have indi- cated similarity. From the user’s viewpoint, has been difficult judge exactly what stone would accomplish. The situation was simi- shoes, and discovering that sizes were not “as marked.” The only resource would guess and hope that fit could found. other words, experience has shown that Rockwell hardness can misleading when the grain structure not exactly the past has caused time losses trying stones, setting machines, actual operation and inspec- tion finished parts. addition cause inaccuracies the stones, manufacturers have costs mounted because the num- many cases. According Midwest engineer- ing data, considerable part the lack uniformity was attributable adhesion between grits; this effected change from the apparent measured hardness and also was the equivalent lack uniformity grit size. Adherence several 55 —-+ +- + + + + j | | | | } | 1 | | | 100 103 — — — + + + + + + + + + + 106 | | | | | 109 —— — —~ = 2s 4+— + + + + + + + + + 118 124 130 Abrasive Uniformity grits together produced one large grain which, especially upon tear- ing away from the bond, would cut faster and deeper than individ- ual grit. This was responsible for scratching the finished part and also contributed some cases too-rapid wearing away the stone itself. These conditions were especially apparent attempts produce metal for instance those sometimes used oil seals. the stone was “hard” enough retain the grits firmly, thus reducing wear minimum and offering extra assurance that the stone would stay flat, the tendency “load up” and stop polishing became great. the other hand, users found that the bond fracture rate was speeded make the stone self-cleaning, the uneven tearing away grits spoiled the flatness the stone. Either condition meant more care and higher costs, with frequent dressing the stone required. The solution offered Midwest makes use grit treatment insure that each grit vented from adhering adjoin- ing grits. said that the treated grits the unbonded state are high capillarity, and that every case the bonding agent finer than the material bonded, complete coating each grit abrasive obtained. This bonding formula referred micro-bond. the flat seals already men- micro-inches (r.m.s.) being ob- tained Superfinish sec. contact time from 18-20 micro- inch ground finish. Formerly, these flat seals were ground, lapped with cast iron laps, and finally finished with India oil surgical stones. typical automotive jobs and some specialized aircraft parts such valve guides, preduction rates have been increased notably SHERMAN Detroit Editor, THE IRON AGE because faster uniform cut- ting rate, fewer stone dressings and less interruption work for changing stones. addition, the absence excessive “tearing away” and wear has greatly increased stone life and the amount pro- duction obtainable from one set stones. The following table, repre- senting automotive application tappet barrels shows economies which have been effected. That stone replacement can Cost each stone Cost for stones Pieces per dressing Minutes dress stones Cost per dressing No. dressings, stone average Dressing cost per stones (full life) Minutes change one stone Cost change one stone Replacing cost for stones Pieces produced per stones Total stone cost plus dressing and changing Stone cost per piece Micro-inch reading average adopted new method rating stones. based, first all, bond hardness and, secondly, the stone density. More correctly, this second factor related the con- trolled pressure used manufac- turing the stones. This provides the user with means for selecting Superfinish stones, incorporating both specific hardness and what- ever stone density required for particular application. Thus, for steel known hardness, suit- able Superfinished stone can se- lected (see illustration): Because accurate control the stone manufacture, the desired combina- tion bond hardness and stone density can obtained. Optimum Stone Average Stone 25¢ each 19¢ each $3.00 $2.28 1165 1044 min 42¢ min min 8¢, men 8c, men $1.60, men $1.92, men 27,634 14,628 $5.26 $4.62 4.2 considerable factor determining production and cost indicated figures from motor company. which now producing 2500 crank- shafts per set stones, compared with 300 400 with stones for- merly used. another instance hardened steel sleeves for tractor engine are being finished with stones that produce 185 liners per set stones, compared with liners per set averaged the past. Following adoption new meth- ods control accurately the qual- ity abrasive stones, Midwest has Tool Angles for Steel Cutting with Carbide—Erratum the article which appeared the March issue under the above title, Harry Wilcox, the title the table printed the bottom was error. The test data apply power con- sumption cutting SAE 1035 steel, instead SAE 1015 indi- cated. The cutting speeds tabu- lated are nominal cutting speeds (lathe dial settings), for which calibration curves are given pp. and 43. THE IRON AGE, May | | | | | | | | | | | | | | | Ag Ultrasonics—A New announcement that the first American ultrasonic gen- erators are now commercially available not only considerable interest theorists but may also prompt some very interesting ex- perimental work. This technique may not quite ready for imme- diate application; however, some the results achieved and some the currently feasible projects which are interest the metal industry are here described. Ultrasonic waves are those vibra- tions which lie above 17,000 cycles per sec. the upper limit human hearing, and their shorter reaches merge with radio and fi- nally light waves. The best known applications today are the inaudible dog-whistle and the submarine de- tector. Intensive sound strong mechanical, thermal and electrical effects. Particularly strong local concentrations en- ergy occur the formation vacua liquids. This called cav- itation. Chambers (J. Chem. Phys. 1937, 290) was able obtain luminescence liquids due cavitation, using sound waves strength. With ultrasonic waves, considerably denser energy trations can achieved. Fren- zel and Schultes (Z. Phys. Chem., Abt. B., 27, 1934, 421-4) found luminescence water “sounded” with ultrasonic waves less strength 500 The production waves has developed lot since Koenig produced waves fre- quency ke. 1899 using small tuning fork. The Galton whistle followed, which produced undulations 100 ke. and when gas and later hydrogen were ap- plied still higher frequencies were reached (up 500 Modern producers ultrasonics are, broadly speaking, two types: the magnetostriction producer and the piezoelectric machine. Magneto- striction the property ferro- magnetic materials expand 48—THE IRON AGE, May COSMAN The Iron Age, New York contract under action magnetic alternating magnetic field, expe- which can used source ultrasonic waves. Langevin used such arrangement when de- vised the submarine detector the last war. Piezoelectricity, discovered the Brothers Curie 1880, the property some crystals un- dergo dimensional changes under the influence magnetic field. These are very small, but can seen clearly under the microscope through the optical lever, and are due changes the free elec- tric charges the crystal lattice. Since here again frequency varia- tions the current will correspond mechanical reflexes the mate- rial, means available send out ultrasonic waves. Modern applications ultrasonic rays are varied and increasing number. But the methods employed are often kept intentionally obscure “inventors” who propose myste- rious “rays” for variety bio- logical processes. With some slight experimentation they able select suitable frequency for ripening and fermentation proc- esses and sell them for often exor- bitant royalties. far the metal working in- good work has been done, far mainly Germany, France and Russia. Little known practi- ‘al applications these methods, but the experimental results are startling and seem most promising. The propagation waves de- pends media. When waves en- counter impermeable object they leave “shadow.” This will clearer and the smaller the wave length relation the obstruction. The permeability metals for sound and ultrasound great. However, fine cracks impurities will obstruct the passage these waves: sound absorption and reflec- tion will take place. shorter ultrasonics give indica- tion the position faults. was the first pro- pose the use ultrasonics testing method. (D. Patent No. 569,598, 1931.) The drawing self-explanatory; ultrasound generator, test piece, cav- ity, receiver (no waves), and receiver (waves recorded). the application this idea, the contacting the test piece with sound generator and receiver has method, proposed Muel- haeuser; the ultrasound generator, the test piece, the cavity, receiver (wave recorded). been great difficulty. When that can overcome, idea will probably find wide application test, the X-ray be- ing necessary only fault en- countered with ultrasonics. Solo- koff (Phys. 36, 1935, 142) testing materials which based upon Debye and Sears’ discovery (Proc. Nat. Acad. Amer. Wash. 18, 1932, 440) diffraction grat- ings “sounded” water. apparatus arranged such fashion that clouded picture graphic plate will indicate fault the tested material. Newton Gaines (Physics, 1929, 209) \ \ , \ S i i Metallurgical Tool emphasizes the possibility using strong mechanical waves (sound, ultrasound) means fatigue testing. Within one hour sound frequency ke. will cause 36,- 000,000 reversals. The values ob- tained experiments are good agreement, according the author. Since the effect ultrasonic waves similar heavy mechani- stresses, the crystal structure materials under will expe- rience percussion shock. Hollmann and Bauch (Natur- wiss. 23, 1935, 35) have found loosening the crystal structure ferro-magnetic material after exposure ultrasonics. Antimony and cadmium, which usually solidify with coarse grain structure, can obtained fine grain state “sounding,” accord- ing Schmidt and Ehret (Z. Electrochem., 1937, 43, 869). Antimony less brittle, while the per sq. mm. The time needed for solidification not reduced, but un- dercooling eliminated. Similar the behavior Duralumin and si- Acad. lumin. Malhoux (C. —This technique, not yet much beyond the theo- retical stage, may means testing metal, de- gassing liquid metal, speeding hardening opera- tions, etc. Sci. Paris, 191, 1930) treated steel with ultrasonic waves and high fre- quency elevated temperatures and—although the experimental conditions are not quite clear his report—the results claims are remarkable. When 0.35 per cent and Cr, Mo, 15-mm. steel bar was exposed 500 deg. for hr. under the influence waves, the hardness was improved from 380 Brinell (Vickers) 1033 with depth penetration mm. The control experiment did not show increase hard- ness and the depth penetration was 0.01 mm. Malhoux concludes that wave treatment the speed penetration nitrogen and improves the case ness. Subjecting chromium-plated ultrasonic generator produced Televiso Products, Chicago. This said the first such generator produced commercially the United States. steel 530 deg. oscillations for hr., depth penetration 0.35 mm. was noted—no penetra- tion took place without agitation. Schmidt (Arc. 1933, 241-5) tried high fre- quency currents nitriding steels with considerable success. But, they find that increased time will not improve depth penetration, the conclusion that mechanical agi- tation will favor nitration seems justified. More recently Solokoff (Acta Physicochemica U.S.S.R. 1935, 930) found investigating the ac- tion strong ultrasonics watts frequencies between 600 and 4500 ke. metallic melts, that “sounded” solidified more rapidly. tests with the structure was more dendritic, in- dicative more rapid solidifi- cation. The investigations Wood, Loomis, Claus and other workers have shown that very fine disper- sion materials can obtained the use ultrasonic waves. These metallic dispersions can produced emulsions and pow- ders. This important for electro- lytic and precipitation processes. The whole technique alloying may undergo changes with the ap- plication ultrasonics. Masing and Ritzau (Z. Metallk. 28, 1936, 293) have been successful al- loying aluminum Schmidt and Ehret, ibid., also dis- persed lead aluminum, and cad- frequency Seemann( Met- allwirtsch. 15, 1936, 1067) dis- cusses the possibility forming mixed crystals with ultrasonics THE IRON AGE, May | } | | | | | } ° ° ° | | | | | | ‘ ta 4 q F cases where there limited solu- bility. The property cavitation will especially useful with metallic melts effect degassing. Small gas bubbles will tend the points minimum agitation, the nodes the ultrasound waves. There they can unite form larger bubbles which have sufficient size rise the surface the liquid metal. (R. Boyle and Taylor, Transac. Roy. Soc. Can. 20, 1926, 245.) Patents have been submitted Germany and Austria which ad- vocate the degassing melts the use ultrasonics. These are also extended high frequency agitation. Not only finest distribution but also the agglomeration finest particles (similar degassing me- chanically) can achieved with ultrasonic waves. Fogs and dust can precipitated—this applica- tion will interesting indus- trial plants. Industry only the threshold developments which may make ultrasonic waves most important piece production equipment. The first firm place the disposal the American market complete equipment for the production these waves the Televiso Prod- ucts, Inc., 2400 North Sheffield Boulevard, Chicago. This firm pro- duces reasonable cost range apparatus for the production ul- trasonic waves. Illustrated herein the smallest model (56). This generates ultrasonic energy rate watts 400 The largest model produces 1600 watts ultrasonic waves. Center Gravity Easy ITHERTO, the method de- gravity machines, cast- ings other units has been based upon calculation. This method hit-or-miss process best and designers have long been concerned about its inaccuracy. The difficulty determining the precise location the center gravity casting obvious. The calculation dependent upon certain assumptions: the homo- geneity, the trueness the casting and the theoretical weight the mat