The Iron Age 1941-07-31: Vol 148 Iss 5

orth »ved with 500 0 x Cost part ition cost tion. ators to new St. dock 0,000 Ont., Cost 420 will prov- tract. has about struc- nd, ildare dition Con- atoon, ilbert, plans about plant Bank re- ronto, Ont., ehouse for yment. nto, Port Port John t, To- Mac- presi- -Clark- Que., o cost fs ASSOCIATED COMPANIES HEAD, WRIGHTSON COMPANY, LIMITED, THORNABY-ON-TEES, ENGLAND AKTIEBOLAGET ARBOGA MEKANISKA VERKSTAD, ARBOGA, SWEDEN JOHN INGLIS COMPANY, LIMITED, TORONTO, ONTARIO, CANADA : y 4 8); ets, ; em- | m.m. B A one ~ PRODUCTS Continuous Strip Coiling Equipment. Continuous Strip Pickling Special Conveying Mechanism. including: Uncoilers, Up-Cut Stitching Machines, Pinch Roll Recoilers, Drying Machines, Units. Tanks, and Auxiliary Press Feeding Equipment. Scrubbing, Leveling, and Strip Uncoiling and Automatic Shearing Vertical Tube Type LEE WILSON ENGINEERING CO. Cleveland, Units. Furnaces. THE WELLMAN SMITH OWEN ENG. CORP., Ltd. Strip Coiling Reels. Tables London, Eng. Sheet Galvanizing Equipment. THE HALLDEN MACHINE Conn. Continuous Pack and Pair THE WEAN ENGINEERING CO. Canada, Hamilton, Ont. Automatic Tinning Equipment. Furnaces. Automatic Doublers. Wheelabrator Abrasive Pubsidiary Company Normalizing Furnaces. THE BRODEN CONSTRUCTION Cleveland, McKay Levellers and Processing Units. Automatic Weight Classifier. Strip and Wire Mill Machinery Strip Welding Equipment. Automatic Gauge Classifier, Automatic Feeding and a ; Editorial Technical Articles Effects Titanium Low Carbon Metallographic Examination Paint Distribution New Vitreous Enameled Murals New Presses Features News and Market Reports News Industry Machine Tool Activity Personals Non-Ferrous Market JULY 31, 1941 Obituaries Scrap Market Comparison Prices Construction Steel VOL. 148, NO. Summary the Week Iron and Steel Prices The Industrial Pace 100 Warehouse Prices District Market Reports 102 Sales Possibilities President and Editor Vice-President and General Manager Index Advertisers Managing Editor News Editor Technical Editor Machine Tool Associate Associate Editor Editor Editor Associate Editor Associate Editor WINTERS Art Editor DIX, Manager Reader Service Owned and Published Washington Editors (Incorporated) MOFFETT JAMES ELLIS Advertising Staff te 621 Union dg.,Clevelanc ice A isi Herman, Chilton Bldg., Philadelphia Chestnut and Sts. 100 East 42nd St. Leonard, 100 East 42nd St., New York Equip JAMES SHERMAN Peirce Lewis, 7310 Woodward Ave., Detroit Cut Cleveland Detroit Ober, 100 East 42nd New York Roll Robinson 428 Park Pittsburgh OFFICERS AND DIRECTORS FRAZAR CHARLES POST EVERIT TERHUNE, Vice-President Boston San Francisco VAN DEVENTER, Vice-President HUGH SHARP JOHN McCUNE Member, Associated Business Papers Vice-President Milwaukee Birmingham Indexed the Industrial Arts Index. WILLIAM BARBER, Treasurer lished every Thursday. Subscription Price: JOHN BLAIR SANDERSON ROY EDMONDS MOFFETT, Secretary te e ates an 2) exi Catt Toronto, Ontario St. Louis JULIAN CHASE, THOMAS KANE, = — 4 : | x / . 64 | | ) ) 106 107 110 112 118 120 ik Q \ é 4 4 ‘ 4 JULY 31, 1941 ESTABLISHED 1855 Managing IME Yes, and time almost everything else addi- tion. Every capable industrial executive knows this true and there- fore spends great deal time managing time. This truth applies and down the line, from foreman president and vice versa. The foreman deals with comparatively small section time compared with that managed the chief executive. The job make his department “run like watch,” that there are missing minutes each hour production. manages the time the men who work under him. The production manager handles broader section time. His job not with individuals but departments. must manage depart- time, and synchronize it, that the various outputs come together meet and fulfill the general manufacturing schedule. The chief executive officer handles still larger section time. his job relate the production schedule plant capacity and both these consumer demand. also part his job, and vitally important one, see that the finished orders get the customers. have really efficient organization, you must have capable time managers each different capacity. The most capable foremen would have their efforts completely nullified incapable production ager. And given good time managers both these capacities, their work would for naught unless there were able chief executive who could manage time that the goods would reach the customer when needed. our defense program, which manufacturing and merchan- dising operation greatly magnified, the manufacturing concerns America correspond the foremen this analogy. The OPM corresponds the production manager. both instances have experienced and capable time managers who know how what they are given do. When comes the general management the program and particularly the responsibility getting the goods the customer, the situation not clear. Mr. responsibilities end with produc- tion. The general timing the program whole and the responsi- bility delivery are other hands. Whether these hands are capable doing their work, soon discover. not will possibly see the greatest piling finished goods inventories that the world has yet experienced. | | | | | j | | | | | j INLAND COPPE Gives Greater Resistance Corrosion Inland Copper-Alloy Steel resists corrosion far better than ordinary steel. This proved many years experience widely varied service applications under most industrial, rural and sea coast atmospheric condi- tions, well Government, technical society and private tests. Typical these tests the eleven-year test rack exposure conducted open hearth pure iron, copper iron, non-copper bearing and copper bearing steel sheets A.S.T.M. Committee A-5. One these tests, made Fort Sheridan, resulted failure the first non-copper bearing gauge (1/32 inch thick) steel sheet the end months. The initial failure copper bearing steel sheet the same gauge occurred SHEETS RAILS TRACK ACCESSO “ ae 3 q 4 q PLATES R-ALLOY STEEL 132 months after the start the test—an added life 100 months. The experiences manufacturers and users have been that the exceptional corrosion resistance Inland Copper-Alloy Steel quickly pays for its very slight additional cost. Equipment and structures made Copper-Alloy Steel last many times longer when exposed atmospheric corrosion, and maintenance costs are drastically reduced. Time lost for making repairs cut the minimum. Its workability and physical charac- teristics are the same non-copper bearing steel. Inland Copper-Alloy Steel can specified all rolled forms, such as; sheets (galvanized and plain), strip, bars, structural shapes, plates, sheet piling and floor plate. FLOOR PLATE STRUCTURALS PILING RIES REINFORCING BARS | Dearborn Street, Offices: Milwaukee, Detroit, St..Paul, St. Louis, Kansas City, Cincinnati, Some Effects Titanium Low Carbon Per Cent Chromium Steel has been shown Com- stock' that the presence small amounts titanium forged pearlitic manganese rially improves the ductility and impact resistance without unduly sacrificing the high strength char- acteristics induced the man- ganese. These results suggested the possible use titanium for tough- ening purposes other alloy steels which the principal alloy hardening element. Accordingly, was decided investigate the effects titanium per cent chromium steel contain- ing 0.20 per cent carbon. Vanadium used commercially such chromium steel (S.A.E. enhance the ductility and impact properties, and view the anal- ogous carbide tanium, was deemed advisable ascertain the relative effects these two elements the chromium steel. The steels studied this investi- gation were prepared 17-lb. in- duction furnace the laboratory the Titanium Alloy Mfg. Co. While tests such small heats may not considered entirely conclusive, was felt that comparative trends would disclosed. All the steels were made with the charge, the same chromium addition. chromium used for this purpose contained 68.83 per cent chromium and 5.32 per cent carbon. Chemi- and Vanadium Forged 1939, vol. 1438, JOHN PAPPAS Formerly, Metallurgical Department, Titanium Alloy Mfg. Co., and MORRIS COHEN Department Metallurgy, Massachusetts Institute Technology cal analyses showed that the basic compositions all the steels ranged the following acceptable limits: 0.18 0.22 per cent car- bon, 0.42 0.50 manganese, 0.021 0.045 sulphur, 0.019 0.034 phosphorus, 0.22 0.30 silicon, 0.98 1.06 chromium. The various special additions this straight chromium steel are shown Table Steel repre- sented the basic analysis, while A-1 was the same composition deox- idized with aluminum. The latter heat was designed develop “in- herently” fine grain size the straight-chromium steel that comparison with the titanium treat- steels would indicate whether the alloying effect the titanium could attributed simply its grain refining action. The titanium added all the titanium-bearing steels Table was the form bon ferro-titanium containing 40.38 per cent titanium, 7.02 per cent aluminum, 3.51 per cent silicon and 0.04 per cent carbon. Steel C-1 was included determine whether the combined action the aluminum and titanium would yield properties not obtainable with either element independently. The vanadium-bear- ing steels (without aluminum de- oxidation) and F-1 (with aluminum deoxidation) were considered repre- sentative the S.A.E. 6120 anal- ysis. The ferro-vanadium used con- tained 40.01 per cent vanadium, 1.97 per cent silicon and 0.055 per cent carbon. Steel was similar steel except that part the latter’s vanadium content was re- placed titanium. The above steels were forged from 3-in. square ingots into round bars for the tensile tests and into square bars for the impact tests. The forged bars were inspected radiographic and hot acid etching methods insure soundness and reasonable freedom from segregation. The bars were then normalized for hr. 1650 deg. F., and cut suitable lengths for the various heat treat- ments. Following these heat treat- ments, the bars were machined into standard Izod impact specimens and sub-size tensile specimens having 1.25-in. gage length and 0.313-in. diameter. The detailed dimensions these specimens are given pages 135 and 132 respectively the Metals Handbook, 1939. Grain Size The grain growth characteristics the steels were established two methods: (1) heating temperatures the range 1650 deg. 2050 deg. for hr., and then interrupting the cooling 1450 deg. for hr. outline the grains with ferrite; and (2) ‘arburizing temperatures the ‘ange 1650 deg. 2050 deg. for hr., and then cooling slowly outline the grains with cemen- tite. these methods grain size determination were em- THE IRON AGE, July 1941—29 : a ¥ 4 : ° ° ° i ig > > J & Tensile strength, 1000 per sq. in. > ’ per cent Reduction area cent Elongation, Izod impact, with 0./0 per cent 30—THE IRON AGE, July 1941 Tensile strength, 1000 Ib. per sq.in. point, Reduction area, per cent Elongation percent impact, 200 190 190 180 180 170 170 140 140 | | | | | | | 4 ] 60 > Oil quench temperature Water carburizing temperature Water quench Water quench Temper 375 Temper 375 deg.F. Temper 375 Temper 375 Temper 375 dea. j * reg * * * x HOR. D S55 ss> > ==> )@A~D S55 ~~ <x amy II HO ~ J 7 ~ ~ ~ ~ ~ ~ L £ c LEFT properties quenched and tempered steels. Base analysis: 0.20 1.00 Cr. Heat treatment follows: normalized 1650 deg. F., quenched water from 1625 deg. F., tempered 600 deg., 800 1000 deg., and 1200 deg. Size treated: in. for tensile specimens, and 9/16 for impact specimens. ABOVE 2—Core properties carburized steels. Base analysis: Heat treatment: normalized 1650 deg. F., pseudo-carburized 1700 deg. F., further treatment indicated. Size treated: in. round for tensile specimens, 9/16 in. square for impact specimens. THE IRON AGE, July 31, | | i ! i ° ° T ployed because these low-carbon steels may used the carburized well the normalized heat treated condition. The essence the grain size study shown Table which gives the coarsening temperatures the steels determined both methods. All the steels were fine- grained (A.S.T.M. 6-8) below their respective coarsening temperatures. The addition aluminum, titanium vanadium (either singly chromium steel markedly raised the coarsening temperature. However, aluminum and titanium were ap- preciably more effective this re- spect than the vanadium. The alu- minum- and titanium-treated steels coarsened abruptly being heated above their coarsening tempera- tures, but the straight chromium steel and the chromium-vanadium this article, the term strength used generic sense include both yield and tensile strengths. only exception this rule was the low reduction area steel after the 1650 deg. treatment. However, this value was not considered truly represen- tative because was obviously out-of-line with the reduction area values obtained after normalizing the same steel the higher temperatures. steel coarsened gradually. abnormal structures were found any the carburized steels. Properties Normalized Steels Table shows the properties the steels after normalizing for hr. 1650 deg., 1850 deg. and 2050 deg. With the raising the normalizing temperature, the straight chromium steel exhibited marked increase and corresponding decrease duc- tility and impact resistance. This indicated that steel was quite susceptible air-hardening. The deoxidation this steel with alumi- num, the case steel produced decrease strength, increase ductility and impact re- sistance, and decrease air- hardening tendencies. The addition titanium the chromium steel had the same gen- eral effect the aluminum, except after the 2050 deg. treatment. The higher titanium steels and (containing about 0.10 per cent and 0.25 per cent titanium respectively were quite resistant air-harden- ing 1850 deg. F., particularly Table Special Alloy Content and Coarsening Temperatures Steels Investigated (Normal base analysis; 0.20 Cr, 0.45 Mn, and 0.25 Si) Special Alloy Analysis, Per Cent Added Heat, Per Cent None None 0.05 0.025 0.10 0.038 0.049 0.101 0.50 0.248 0.16 0.15 32—THE IRON AGE, July 31, Coarsening Temperature, Deg. Ferrite Cementite Remarks Method Method Straight 1675 1675 chromium steel Deoxidized with 1900 1950 addition 0.05 per cent 1830 1830 1950 1950 Deoxidized with 1900 1950 addition 0.05 per cent 1950 2000 1950 2050 1850 1850 Deoxidized with 1950 2050 addition 0.10 per cent 1850 1950 indicated their high ductility and impact resistance; but, unlike the aluminum-treated steel they underwent sharp increase strength and decrease impact re- sistance after normalizing 2050 deg. Although the coarsening the uncarburized condition were below 2050 deg. F., this was also true steel A-1. Hence, the mark- air-hardening these two ti- tanium steels after the 2050 deg. treatment could not attributed enlarged grain size. More likely, some the titanium carbide cyanonitride particles the higher austenite this high temperature, and thereby greatly increased the hardenability. Excellent ductility was obtained steel C-1 with the combined use aluminum and ti- tanium. general, for the normalizing treatments used the vanadium-bear- ing steels greater strength and lower ductility than all the other treated steels. The chromium-vanadium steel was the most susceptible air-harden- ing; even normalizing 1850 deg. strength and decrease impact resistance compared the nor- malizing 1650 deg. the other hand, the addition either aluminum titanium with the vanadium, steels F-1 and inhibited the air-hardening after the 1850 deg. treatment. Amongst the three vanadium-bearing steels, steel generally exhibited greatest strength with lowest ductility and impact resistance; steel F-1 showed just the reverse; and steel had intermediate other words, despite its low vanadium- content, steel displayed excel- lent balance strength, ductility and toughness the normalized condition. Quenched and Tempered Steels Fig. illustrates the properties the steels after water quenching from 1625 deg. and tempering 600 deg., 800 deg., 1000 deg. and 1200 deg. Except for the vana- dium-bearing steels when tempered 1200 deg. F., the straight-chro- mium steel had higher strength and lower ductility and impact re- sistance than all the other steels. Deoxidation with aluminum (steel A-1) produced marked improve- ment the ductility and impact values, but only the expense large decrease strength. H H No. A-1 | The addition titanium the pase analysis also strength and raised the ductility and impact resistance. These ef- fects increased proportion the titanium content, and wide range properties was developed. For proximately 0.10 per cent titanium had about the same ductility and impact resistance the aluminum- deoxidized steel A-1, vet had higher strength. Similarly, steel with approximately 0.25 per tanium had about the same strength steel A-1, but was more ductile and resistant impact. the comparison steels C-1 and was evident that the addition titanium the aluminum deox- idized steel improved strength and the ductility, but low- ered the impact resistance. The aluminum-deoxidized steel C-1, con- taining about 0.05 per cent ti- Steels and Vana- dium Corp. America, New York, 28. 5This medium not recommended for was found that some carburization takes place, and machining after ment becomes difficult. tanium, had very similar properties steel which contained twice much titanium. The vanadium steels group displayed greater retention strength after tempering than any the other steels. Among the vanadium-bearing steels, steel had the best combination prop- erties. general, the strength, ductility and were substantially equal to, bet- ter than, the corresponding prop- erties the higher vanadium steels and F-1. may also noted that steels and F-1 had consider- ably lower ductility and impact values than those reported for S.A.E. 6120 This fact sug- gests that the experimental com- positions investigated may ex- pected show greater ductility and toughness when made large scale heats. impact Suitable lengths bars round for the tensile tests and 9/16-in. square for the pseudo car- tests) were Pseudo-Carburized Steels normalized burized cast iron chips’ for hr. 1700 deg. F., and were then given the following treatments: Treatment Box cooled from car- burizing temperature. Oil quenched from 1625 deg. Water quenched from 1450 deg. Air cooled from 375 deg. Treatment Oil quenched from the carburizing temperature. Water quenched from 1450 deg. Air cooled from 375 deg. Treatment Box cooled from carburizing temperature. Water quenched from 1525 deg. Air cooled from 375 Treatment Box cooled from carburizing temperature. Oil quenched from 1625 deg. Air cooled from 375 deg. Treatment Oil quenched from the carburizing temperature. Air cooled from 375 deg. The properties the test speci- mens machined from the bars after the above heat treatments are shown Fig. Asa general rule, the best combinations properties were produced treatments Table MECHANICAL PROPERTIES NORMALIZED STEELS Normalizing Yield Tensile Temperature, Strength, Strength, Deg. Lb. Per Sq. In. Lb. Per Sq. In. 1650 55,000 85,500 1850 58,200 97,000 2050 68,500 111,000 1650 78,500 1850 51,000 87,700 2050 52,500 90,000 1650 58,500 80,300 0.025 1850 55,000 81,900 2050 60,300 97,800 1650 51,700 78,000 0.038 1850 57,400 93,100 2050 67,200 102,000 1650 52,000 81,700 0.049 1850 52,700 79,200 2050 50,200 87,700 1650 48,800 76,600 0.101 1850 53,000 78,600 2050 61,500 98,800 1650 46,800 78,000 0.248 1850 60,000 83,000 2050 75,500 111,000 1650 62,400 84,700 0.16 1850 80,000 108,500 2050 82,800 115,000 1650 56,200 81,000 0.15 1850 56,600 84,300 2050 70,800 106,000 1650 61,100 85,600 0.028 0.09 1850 65,700 87,800 2050 75,800 112,000 Deoxidized with addition 0.05 per cent Al. Deoxidized with addition 0.10 per cent Al. Reduction Elongation, Area, Impact, Per Cent Per Cent Ft.-Lb. 26.0 58.0 47.0 20.0 53.5 12.0 14.0 47.0 2.5 30.4 63.0 81.0 27.2 61.5 60.0 24.8 53.2 25.0 31.2 58.8 65.0 28.0 61.0 29.0 22.4 55.2 32.0 64.2 74.0 62.5 13.0 22.4 53.2 13.5 32.8 68.0 74.0 32.9 65.1 47.0 27.2 63.9 7.0 32.0 66.2 70.0 32.0 64.1 51.0 28.0 60.5 4.0 32.0 68.5 73.5 32.8 70.5 62.5 20.8 54.8 6.5 28.8 60.0 58.0 20.8 55.2 15.0 17.6 46.4 2.5 32.8 65.6 71.5 27.2 63.1 68.5 21.6 58.3 11.0 28.0 56.1 70.5 27.2 57.8 20.0 56.4 3.0 > | r il e 4 | iy | l- i- THE IRON AGE, July and each which involved only three treatments, resulted the highest strength and the lowest strength, but the latter was counterbalanced excellent duc- tility and impact resistance. Not- withstanding the produced treatment the duc- tility was good and the impact re- sistance fair. Treatment which involved direct oil quench from the carburizing temperature usually developed properties intermediate between those produced treat- ments and Treatments and which included double quenching good tensile strength but the yield points were disproportionately low. Furthermore, the accompany- ing ductility and impact values were slightly inferior, the aver- age, the corresponding values de- veloped treatment yet the latter treatment produced the highest tensile and yield strengths all the treatments. agreement with the previous results, the straight-chromium steel showed the highest strength, but rather low ductility and impact re- sistance. Deoxidation this steel with aluminum markedly lowered the strength after all treatments, but improved the ductility only af- ter treatment and improved the toughness only after treatments and The addition titanium the straight-chromium steel usual effect lowering the strength and raising the ductility and im- pact resistance, with the highest ti- tanium greatest effects. the case the quenched and tempered treat- ments, the aluminum deoxidized steel C-1 containing about 0.05 per cent titanium had properties steel which con- Steel with about 0.25 per cent high ductility and tance except after treatments and where the impact values were not any higher than those the lower titanium steels. This ex- ception was accounted for the fact that metallographic examin- ation the steel impact speci- mens used for treatments and disclosed considerable segregation titanium cyanonitride. steels, steel containing 0.16 per cent vanadium seemed have the best combination properties; yet the superiority over the lower slight. Conclusions (1) The addition aluminum, cent chromium steel containing 0.20 per cent carbon raises the coarsen- ing temperature. The effectiveness these elements this respect de- creases the order named. (2) The addition titanium the above low-carbon per cent chromium steel lowers the strength properties and raises the ductility and impact properties. this re- spect, the titanium behaves more like aluminum than vanadium. How- ever, the titanium produces better combination properties than obtained aluminum deoxidation alone. Hence, the effect the ti- tanium not simply one deox- idation and grain refinement. The titanium has specific alloying ac- tion. (3) Aluminum and titanium in- hibit air-hardening these steels after normalizing temperatures Physical Properties Magnesium Alloy the article Sand Ford Motor Co., THE IRON AGE, July 10, table page listed Tensile Strength, Lb. Per Sq. In. cast 27,000 Heat treated 36,000 Heat treated and aged 40,000 the physical properties mag- nesium alloy No. 50. This table was error, and should have appeared follows: Yield Strength, Brinell 12,000 16,000 20,000 34—THE IRON AGE, July 31, 194! 1850 deg. However, after normalizing 2050 deg. F., the air-hardenability the titanium- bearing steels increases markedly, probably due the solution the titanium carbides Vanadium, the absence alumi- num titanium, raises the air- hardenability after normalizing 1850 deg. above. (4) the pseudo-carburized and heat treated steels, well the quenched and tempered steels, ti- tanium contents between 0.025 and 0.25 per cent produce wide range mechanical lower titanium steels exhibit high strength with moderate ductility and impact resistance, while the higher titanium steels exhibit mod- erate strength with high ductility and impact resistance. (5) The combined use alumi- num and titanium may advan- tageous attaining given set properties with less titanium than would required the absence aluminum. (6) The hardened vanadium- bearing steels show greater ability retain their strength after tem- pering than steels. This property not im- paired the reduction the vana- dium content from 0.16 0.09 per cent and its replacement with about 0.03 per cent titanium. With this substitution titanium for part the vanadium, excellent balance properties may obtained. Acknowledgments The authors wish acknowl- edge the effective cooperation the Titanium Alloy Mfg. Co. carry- ing out this work. Special credit due Wolf for the making the steels and Comstock for many helpful suggestions. S.A.E. No. the incorrect table the terms “Heat Treated,” and “Heat Treated and Aged” were interchanged, and the second value for Brinell hard- ness listed was shown instead 58. This former value slightly higher than ordinarily obtained with the solution treatment only. mentioned elsewhere the article, the aging, precipitation treatment gives more strength and hardness sacrifice ductility. i i ° ° ° SHERMAN Detroit Editor, The Iron Age ° more than decade there has been use Ford Motor Co. method for rapid duplica- tion most kinds dies and molds which some cases has saved per cent the time ordinarily employed making dies. Because large volume production—in some cases requiring many hundreds sets duplicate dies yearly—has been associated now only with the automobile industry, little at- tention seemingly has been focused this important process. Indus- try, and large, forgot what may have heard about the process, perhaps because could see little chance apply widely. The defense program has, among other things, widened the interest general industry problems tooling for mass production. has expanded the output many plants that they are—frequently for the first time—in need tooling such large scale that they, too, will need many duplicate sets dies fulfill contracts. This change the status many industrial plants has been important factor reviving in- Die Typing Speed Production —With more speed" the cry the day, this method producing duplicate dies for forging, sheet metal work, plastic molding, die castings, etc., par- ticular importance. Also notable are the increases die life and savings expensive die steels. terest the Ford die manufactur- ing technique. First described near- years ago (THE IRON AGE, March 17, 1932), forging process die making, commonly called “die typing.” Essentially, the die typing proc- ess starts with slightly oversize “cut” die which used forge blocks die steel which turn are used for the forging sets pro- duction dies. The process one calling for great accuracy and perfection surface finish each stage. eliminates machine work the production die impressions. Twelve years ago, engineers began experimenting typing method duplicating dies. Since that time more than 200 dif- ferent automotive parts, many them difficult forgings, have been produced from such typed dies. The dies have been employed also for variety trimming, forming and molding operations. The first advantage attached the use typed dies the spec- tacular reduction time required produce finished set dies. Second, has been demonstrated that the forged die structure has greatly improved life, attributable the hot working the die mate- rial during the forging typing operation the die. Productivity die sets was found increased about twice over that usually re- corded. Accuracy production parts produced these dies was ob- tainable within very close limits. Third, the dies have been produced small inserts larger die retain- ing blocks—an obvious economy since inserts can changed re- peatedly without great loss die material. Comparison with Die Sinking Conventional die sinking la- borious and costly, requiring that considerable skilled work done hand, even where most advanced die-sinking techniques are em- ployed. More recently the use automatic engraving machines form millers, which machine die blocks their approximate work- ing shape transferring contours from three-dimensional model the die block, has speeded die sinking, but even these dies must finished portable power tools and hand remove cutter marks and general work the impres- sions the final size and finish de- sired. Die typing can never replace die THE IRON AGE, July 1941—35 ’ i t \ 7 | | n | } Ss . le 4 1s | od iy. sinking since, will seen, the original, master impression must cut out solid metal. Where die typing has been proved economical cases where more than about sets duplicate dies are ordered time. Duplicates are required where production rates are high enough make necessary have several sets dies operation one time; where spares are required insurance against down time; replace worn out dies; and tool auxiliary plants and sub-contract operators. Early Automotive Practice Ten years ago some automo- bile plants performed operation IG. ob- ject such this, the die typing proc- ess starts with mas- ter-master die. that resembled both die hubbing and die typing some respects. During this period, when required service parts were longer stock, was the practice some forge shops take sample the required part steering ball arm, for instance) and press into heated block steel, thus forming the crudely shaped die cavity. This cavity was finished hand and then was used forge the required service parts, the usual production being 100 300 parts from this type die. Analogous Hubbing Process starting point the de- scription die typing, may compared die hubbing (some- times called die hobbing) which superficially, although there are important differences the technique and the results. The chief difference that die hubbing done cold, while die typing done hot, different types die steel being used for each process. Die hubbing employed mak- ing dies for plastic moldings, for jewelry embossing, for dies used die casting, etc. This accom- plished making hardened steel model the object for which the die mold intended. This model impressed under pressure approximately 200 tons per sq. in. until forced half way into very soft block steel ingot iron 36—THE IRON AGE, July 31, 1941 room temperature. The process most applicable cases where symmetrical object involved, since the model can turned lathe, for example. Until recently, dies made the hubbing process were formed non-hardening material, uses are somewhat restricted ac- cordingly, but there are now three hubbed molds available. The hub- bing process, however, imprac- ticable for making dies that will involved severe usage, such forgings. die typing, the im- pression formed while the die block hot, that through-hard- ening steels can used ordi- nary forging die practice. Die-Typing Procedure the decade during which the die typing process has been use, standard shop procedure has been developed and, along with it, some terminology new the die-making industry has also been developed. For clarity the process will de- scribed with reference simple object (Fig. although the object might well connecting rod, IG. 2—Vertical cross-sec- tional view through the machined die prepared master-master. camshaft, automobile steering spin- dle, any shape ordinarily forged molded. New terminology, when introduced, will explained. understood that even though de- scription may limited single die block, applies pairs sim- ilar dissimilar blocks, whichever are required. obvious that part such that illustrated Fig. would forged from die cut in- made forging process, the master die must embossed, cameo relief. Because cutting cameo-like die exceptionally ex- pensive and time-consuming, the die typing process makes use master-master die instance like this, can produce the em- bossed die forging from in- taglio die. This, sounds con- fusing, will explained text. For the object pictured Fig. the die typing process starts with master-master die (sometimes re- ferred the female This used forge number embossed master dies (sometimes referred male master dies). These are sometimes also referred the typing dies, since from them that the required num- ber sets production dies are typed forged. essary incorporate draft angles the die design and allowance must made for shrinkage. How- ever, allowance for triple shrinkage must made the die for die typing for all the hot metal work (forgings, etc.), one shrink being anticipated when the master typing die forged from the master-master, another when the production die forged, and the final shrink when part forged. any event, least double shrinkage necessary, with the first shrink eliminated when the dies are used for cold forming. Aside from the re- quirement triple shrinkage, and the occasional necessity venting die drilling small holes per- mit the escape gases during the forging process, die design appears present special problem the shop employing the typing process. The master-master die cut ac- cording conventional practice but the die block only moderately larger than the die impression made it, since all the dies are retainer block. greatly facilitating the typing process, this advantage because elim- 3—The typed die and the master-master die are shown here inserts retaining blocks. the usual practice han- dling very large heavy die blocks, even for small jobs, and also re- duces the amount die metal circulation the shop. The scrap- ping die material greatly re- duced this practice, also. Fig. vertical sectional view through the machined die prepared with this process. The die typing process makes use insert retaining block provide the mass usually associated with forging die and also pro- vide means attaching the power press hammer. Such insert retaining block used the typing process, itself, and the production parts made from the typed die. Forging Typing the Die The first step the die typing process illustrated Fig. which represents diagrammatically section through the die blocks power press hammer, showing the master-master die illustrated Fig. supported the upper die member and illustrating male die, master die, having been 4—The typed die produced the initial step will have the form shown here. formed typing. The typed die, and the master-master die, are shown inserts retaining blocks which are turn mounted the press head and bed conven- tional manner. the view shown, the master- master die was shrunk into its re- taining block before the forging op- eration began; the typed master die was first only squared billet steel, but the forging opera- tion has been expanded fill the recess its Upon cooling can easily forced out with the knock-out pin acting through the hole shown sketch. When necessary re- move the master-master die from its -retaining block, driven out with the knock-out pin after the retaining block has been heated approximately 850 deg. and the insert cooled means water spray. The typed die produced this initial step will have the form shown Fig. (It only neces- sary square the die insert after removal from the retaining IG. 5—This the manner which the male die, type, employed for forming the die insert block employed for produc- tive purposes. block—the die surface required Fig. illustrates the manner which the male die, type, em- ployed for forming the die insert block employed for productive purposes. Fig. shows set fin- ished die blocks, inserted tainer block, mounted the press hammer, and ready for produc- tion the part illustrated Fig. Use Retainer Blocks The insert retaining block shown cross-section and provided with parallel side walls the upper por- tion. The side walls the lower portion the recess are tapered slightly outward provide the draft conventionally employed connection with forging other corresponding dies. The depth the upper portion corresponds sub- stantially with the depth the master-master die. The draft shown the recess the lower retainer block not abso- lutely essential since the cooling the heated metal will free the die insert, anyhow. IG. 6—This set finished die blocks ready for production part shown Fig. the forming these dies, only sufficient hot metal placed the depression the lower retainer block insure complete filling the depression and complete forma- tion the die itself. The flash, shown Fig. below the actual die impression and the metal forming flowed di- rectly from the main body the hot billet there tendency deform the working face the die. the flash were formed the plane the upper, working face, the die, the metal forming the flash would flow transversely out- ward from the cavity into the flash and there would tendency for the flowing metal pull away from the type the upper edge the cavity. Effect Also important the success the die typing process the fact that the insert the hammer mounted deep its recess. Then the side walls the recess provide retainer ring wall the heated billet, its forming stages, lat- erally supported. This prevents controlled flow metal and results the true forging typing action that required. Finishing the Production Die The production die insert, after being removed from the typing block, machined the side and bottom faces and usually machine work The side faces may machined square with the top face (as the case the master-master die and the type block) and retained the re- tainer block merely shrink fit, the sides may slightly tapered inward toward the bottom, about in. taper per ft. Inserts driven into THE IRON AGE, July | | irs S. ire la tly his the Metallographic last week's description method devised Germany reduce all the relevant metallographic in- formation about steel series numbers. Herein, conclusion, data are given classifying inclusions, car- bide segregation, other structural phenomena, and sur- face condition. evolved bearing inclusions, with value numbers indicated for size and frequency: 1.01.0 the series for the estimation phide inclusions, and these bluish- gray islands (see also Fig. are given value numbers from from the smallest and most infre- quent the largest and most fre- quent. These inclusions occur steels from acid and basic open and electric furnaces: 1.02.0 defines brittle oxide slag inclusions, mostly Al.O,. They occur forged billets usually distinct from ABOVE IG. inclusions occurring particularly steel pre-melted the basic open hearth and finished acid. Note that the sulphide lens are included dark oxide inclusions. 100 diameters; reproduced here about one-half size. RIGHT 3—Special cases non- metallic inclusions basic steels. 100 diameters; reproduced about one-half size. IRON AGE, July one another, single spots lines. Acid open hearth steels have mostly smaller inclusions, while basic open hearth steels which they occur more rarely, carry isolated and larger inclusions clean ground mass. They not occur other grades steel. Basic electric steels require greater number SMS designa- tions: that is, 1.03.0 for coherent oxide slags ball shape (see Fig. last week); 1.04.0 for coherent oxide slags oval shape; 1.05.0 for coherent oxide slags line shape; 1.06.0 for coherent oxide slags 1.03.6 1.03.4 double lines streaks; and 1.07.0 for coherent oxide slags multi- point patterns. The value number the signif- icant number was determined the area inclusions. volume determination would, course, more accurate but the system here- meant for service conditions and should not carry beyond. seems worth noting that these in- clusion forms rarely occur together the same steel; for, the many inclusions few are typical for each works, betraying individuality the production however, offers possibility esti- mating origin and quality steel the analysis sufficient num- ber specimen. The steels made the basic open hearth showed SMS 1.01.0, sulphide series, varying size and fre- quency. Dark oxide inclusions sulphide lens were found significant for duplex melted basic furnace and finish- acid. may happen that in- 1.05.6 1.03.5 | ° ° Translated ° ° clusions are encountered which in- dividually would belong separate classes. Here the SMS figure found adding together the values ing inclusions one class, then the SMS value will found ere- readily. However, would cum- ions bersome attempt take all the combinations possible. steels from the high frequency ther furnace particularly wide variety lany inclusions have been observed each even within one cast. Here, also, the method manufacture seems more important than with the other esti- methods. Figs. and show SMS for Cr-Ni and Cr-Mo steels, mostly they were made the acid open open hearth seems justified. hide The SMS 1.11.0 1.14.0 (see 1.06.5 fre- Fig. refer the segregations 4—Standard metallographic series for slag inclusions Cr-Ni steel. and inclusions free cutting steels. This corresponds Fig. 100 diameters; reproduced about Since these steels must contain pre- large number inclusions, SMS have been developed apply this in- class. With these series uniform and concise evaluation segrega- tional inclusions free cutting steels has been made possible for the plant. While measuring proc- nor physically exact, possible give speedy information for practi- cal purposes regarding the non- metallics the steel. The procedure adopted for the 1.06.3 evaluation was found this: note made the highest value number found the polished sec- tion (Fig. and this adopted the standard. If, however, there are — island inclusions, then their number steel and the frequency should for instance, 1.05.4, ete. While sulphide and carbide segregations can only described such 1.06. SMS, for oxides the shape and line picture also defined. has been 5—Standard metallographic series for slag inclusions Cr-Mo steel. found desirable show the position This corresponds mainly Fig. 100 diameters; shown here the test piece within the steel. one-half size. { THE IRON AGE, July ° ° , The Age, New York | g 1.14 1.12.2 1.13.2 1.14.2 111.3 1.12.3 1.13.3 1.14.3 ~ * 3 1.11.4 1.12.4 1.13.4 1.14.4 - = . 1.12.5 1.13.5 1.14.5 ~ 1.11.6 1.12.6 1.13.6 1.14.6 “a. 1.11.0 1.12.0 1.13.0 1.14.0 Fig. 6—Standard metallographic series for slag inclusions free cutting steels. 100 diameters; shown here one-half size 40—THE IRON AGE, July 31, H } = i : 4 specimen comes from the sur- face, prefixed; intermediary and center zones are shown and Every sectional area yields test pieces least, and value numbers the cuts are noted—the sum gives quality and vergence the values greater with oxide than with sulphide carbide segregations. Averages ob- tained different observers different points agree well. Greater series are evaluated finding mean value for carbide, sulphide From 1.03.0 and 1.05.0 IG. 7—Pattern structure, and slag investiga- tion and its evaluation. First column gives current numbers, second gives number section, and fol- lowing are sulphide and oxide slag inclusions and carbide segregations. Sixth column the sum and finally there space for special re- marks, e.g., titanium nitrides, cementite lattice, etc. Also mentioned are source steel and dimensions. and oxide segregations, first singly and then taking the total. Development these series led clear picture, distinguishing both source and process smelting showing the typical picture inclusion size and shape for each plant. However, must repeated that the total picture significant large measure for each type furnace and one inclusion type defines the furnace, since they all occur all furnaces with varying frequency and size. Certain points have clearly emerg- ed, however: steel showing 1.01.2 1.01.4 without line ball shaped oxide inclusion usually acid open From 2.04.0 hearth steel. steel with 1.01.05 the most 1.01.15 with line and ball shaped oxide should basic electric steel. Acid steels are distinguished the large number evenly distributed smaller and inclusions series 01.0 and 02.0, shown Fig. (last week). steels, especially those from the electric furnace, show few large oxide inclusions variety shapes, overwhelming- the series 1.03.0 and 1.05.0— these are found only after pro- Vereinigte fabrikenA.G. longed search. All these facts can separating steels that have been mixed delivery the plant, without resorting chemical anal- ysis. The inclusion size depends the degree deformation, but billets and slabs 120-mm. diam- eter square show marked di- vergence values. Material di- mensions can accounted for relative evaluation. Clearly, for the same purpose certain part the inclusions may greater smaller relative their size. segregations, SMS 2.00.0 are caused the concentra- und Schlackenuntersuchungen tion cementite certain points. this series 0.5 used value number since very pure steels exist and already designates strong segregation. SMS 2.07.0 represents C-segregation series high car- bon tool steel (12 Cr, low degree deformation results coarse concentrated double car- bides, value number while num- ber shows good distribution, that steel with toughness and good cutting properties. According works requirements the material Werk Schweinfurt Laboratorium control post should apply SMS establish usefulness otherwise the material. The hardening and treating high speed tool steel Co, W), will discussed later under SMS 4.00.0. The SMS 3.00.0 designed show line structure measurement high grade Cr-Ni and Cr-Mo steels for exacting service. Primary and secondary line structures occur, first after solidification and then after secondary crystallization the solid state. Origin and influence these line structures are well known. Since the line structure can very detrimental, de- sirable classify according THE IRON AGE, July 31, 23. i Me. 1 & Din Ba Annealed Annealed Anneoled at ECN ECN Spring Steel Ball Bearing Structure Cast Structure (0.4% 0.8% Steel case depth. 4.01.0 4.03.0 4.05.0 4.06.0 42—THE IRON AGE, July 31, 4 4.03.1 4.05.1 4.03.2 4.05.2 4.05.3 4.03.3 4.05.4 4.03.4 4.06.5 4.05.5 4.03.5 i High Speed Tool Stainless Steel (0.4% Cr) 13% 5% Co: 4.5% Cr) 0.3 UPPER RIGHT IG. 9—SMS for surface ball bearings. Value 100 shown here two- thirds size. LEFT IG. 8—Standard metallographic series for hardened structure struc- tural and tool steels. SMS 4.02.0 and 4.04.0 were left out because they ap- plied steel unknown analysis. ECN case hard- ening steel 3.5 per cent Ni, 0.75 and 0.15 1000 diameters; shown here one-half size. 0.2 £4 \ ¥ } aS 0.4 SMS series. Thus, tolerances can established according the purpose the part. They should established for each case, show- ing the influence the line struc- ture the particular application. Structural Phenomena the SMS 3.00.0 and 4.00.0 the ferritic and pearlitic structure unalloyed steels and the influence heat treatment and cold work the grain size are discussed. Apart from carbide formation, grain size these materials influences prop- erties and appearance the sur- face. Therefore, standard series was evolved covering the whole practical range grain sizes. Af- ter permissible limits have been de- fined, the SMS are quite satisfac- tory, efficient and Macrographic examination tech- nological testing may series also, e.g. the estimation grain size fracture examination, the testing cracks rivet heads. But these tests must complemented microexamination. Styri and Walp (Metal Progress, vol. (1931), 79) apply standard series the examination tool and structural steels per cent showing the structure hardened but not tempered. The optimum range for both hardness and machinability lies between 170 and 200 Brinell, but this value does not define the steel sufficiently and necessary complementary. The un- [CONTINUED PAGE 96] THE IRON AGE, July 31, Annealed | 4.07.1 4.07.3 4.08.3 4.07.4 4.08.4 4.07.5 4.08.5 Steel 4.07.0 4.08.0 IRCULATING systems now paint many different colors the half hundred points actual application shelv- ing, steel furniture, kitchen cabi- nets, lockers and other metal prod- ucts they come production lines the plant the Berger Mfg. Division, Republic Steel Corp., Canton, Ohio. The sys- tems extend about two miles. Seven pipes are one system and two another. Prior installation the new centralized paint mixing and cir- culating equipment, enamels and lacquers had been delivered 50- gal. drums four widely separated mixing stations located near the various finishing areas the plant. There, required, the finishing materials were prepared for use reducing with thinners, stirring hand with wooden paddles for min. etc. Spray operators had once every hr. refill the con- tainers from which they sprayed. Paint material mixed hand wit different locations, different tem- peratures, different times, and not one individuals, could not consistent viscosity, specific gravity degree agita- tion—all which have direct bearing the color uniformity obtained. Certain advantages derived from the centralized mixing paints were, therefore, fairly obvious. Most important, continuous mechanical agitation could used, more complete dis- persement pigments obtained, and homogeneous solution main- tained all times. Also, more uniform temperature maintained mixing room than under any other conditions. Viscos- ity and specific gravity tests could always made under the same conditions and would, therefore, more directly comparable. The fire hazard could materially reduced. The DeVilbiss equipment consists two centralized mixing and paint Paint Distribution Stream | | Fic. the mechanical paint mixing unit. ‘ storage rooms from each which circulating systems fan out sev- eral points two floors the plant. the larger the two mix- ing rooms there are mixing seven paint circulating systems. Five the seven lines carry paint equal number spray booths the first floor spray room. Two group four spray booths the second floor the plant. paint line serves the second floor booths only. seventh line runs group dip enameling tanks lo- cated the first floor. The smaller mixing nine mixing tanks from which two circulating systems carry paints the locker assembly lines. Together these two vide air-conditioned ities for more th