The Iron Age 1941-11-20: Vol 148 Iss 21

NOVEMBER 27, 1941 TWO SECTIONS—SECTION ONE PROTECTED ing and finan- cial. must perform the complete satisfaction the mill operator. This assurance the successful operation Timken Roll Neck Bearings entirely independent any guar- antee that the mill manufacturer might give covering the equipment whole. WHEN you the Timken Bearing application has been ap- proved our engineering department, the mill builder has responsibility far the roll neck bearings are concerned. the other hand, our in- terest the bearings never ceases from the moment they into service. You thus can specify Timken Roll Neck Bearings for old new mills confident that your investment fully protected. THE TIMKEN ROLLER BEARING COMPANY, OHIO Manufacturers Timken Tapered Roller Bearings for automobiles, motor trucks, railroad cars and locomotives and all kinds industrial machinery; Timken Alloy Steels and Carbon and Alloy Seamless Tubing; and Timken Rock Bits. TRADE-MARK REG. TAPERED ROLLER BEARINGS Ve Crane YOURE means will wear The vital parts crane are the wearing parts. When crane quiet, means ROLLER BEARINGS that the friction and wear which cause noise, expensive maintenance, and time- consuming shut-downs, have been eliminated. Whiting cranes have been de- Reduce Noise and Wear signed for smooth, efficient, quiet-running operation. WHITING Cranes When you visit shop equipped with Whiting cranes, note how every vital part protected against excessive wear. You will find that precision-cut herring- The smooth, frictionless bone gears, each point speed reduction, transmit power quietly and ment Whiting cranes due, ciently—that heavy duty roller bearings keep the gears permanent alignment and reduce friction bearings and shafts. Flexible couplings between the driving prevent high motor and gear reduction units prevent vibration and binding. Tapered-tread starting loads, drive wheels keep the crane squarely the runway. and make fast Quiet-running Whiting cranes are available capacities from one 400 tons. acceleration Also electric hoists from tons. Whiting Corporation, 15601 Lathrop Ave., Harvey, Builders quality cranes for over years. OVERHEAD TRAVELING bearings, which eliminate wear, ‘ ( Crane VOL. 148, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor, LIPPERT News Markets Editor, ROWAN Machine Tool Editor, OLIVER Associate Editors JAMES Art Editor, WINTERS Editorial Assistants Washington Editor MOFFETT Resident District Editors CAMPBELL HERMAN KLEIN Pittsburgh Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis Newark, Seattle ° ° ° DIX, Manager Reader Service Advertising Emerson Findley Robert Blair Union Bldg., Cleveland Herman, Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 42nd St., New York Robinson Fitzgerald Park Bldg., Pittsburgh Don Harner, 1595 Pacific Avenue, Long Beach, Cal. Johnson, Market Research Hayes, Production Manager. Baur, Typography and Layout. ° ° ° Vear Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts nes lished every Thursday. Subscription Price United States and Possessions, Mexico, Cuba, and South America, $6.00: Canada, move Foreign, $12.00 year. due, copy, cents. roller Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Office Advertising Offices Chestnut and Sts. 100 East St. Philadelphia, Pa. New York, U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. S. HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE VAN DEVENTER, Vice-President Vice-President Vice-President Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Editorial One Way Doors Technical Articles Conservation Aluminum Measuring Fluidity Cast Steel Hydrogen Embrittlement Casting Pit Refractories Guideless Bar Straightening Machine Mold and Core Washes Features Assembly Line Washington West Coast Fatigue Cracks News and Markets This Industrial Week News Industry Government Awards Personals and Obituaries Construction Steel Machine Tool Activity Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices Warehouse Prices Sales Possibilities Products Advertised Index Advertisers Copyright, 1941, by Chilton Company (Inc.) This Week in... 104 ° ° ° WESTINGHOUSE “DE-ION” WESTINGHOUSE MOTOR WATCHMAN “DE-ION” LINESTARTER Manual Across-the-line Starter Magnetic Across-the-line for Motors hp. Starter CLASS 10-100 CLASS 11-200 Quick make, quick break toggle action prevents contacts. ‘‘On,” “Tripped” positions self-in- Push-button operated—built- mounted Small, compact construction saves space. Bi-metal over- load protection hand automatic reset. protection for contacts re- protection for contacts. Ample wiring space. Rust-resisting duces maintenance. Vertical parts. Silver contacts. Key- magnet operation speeds con- hole mounting for quick, easy tact opening and prevents installation. accidental operation. 3 WESTINGHOUSE WESTINGHOUSE SAFETY SWITCH AB-I BREAKER Diamond-pointed break jaw Bi-metal overload protection. and extended-blade construc- protection for con- tion Prevent burning and tacts. Saves maintenance beading contacts. One- time and production time— construction circuit outages can re- parts exposed. Door opens quick-break Types and only when switch “Off” Ample for position. Occupies approxi- 75-V switches. quenchers 575 switch and fuses. J-21148-A your .neares stinghouse Sales Office Distributor — THE RON AGE NOVEMBER 27, 1941 ESTABLISHED 1855 One Way Doors free country the citizens have freedom action, limited only the law, follow their peaceful and legitimate pursuits, one which earn living. Another attribute free citizen the right change his mind. Take these rights away from free people normal times and freedom becomes slavery. Under certain circumstances, course, government has the right and the duty restrict these freedoms. times national emergency, for example, the $2l-a-month draftee cannot pack his belongings and leave camp because dissatisfied with wages, hours working conditions. Nor can Mr. Grace Bethlehem say don't think will make any more armor plate build any more nor can Mr. Keller Chrysler change his mind about making tanks. Government alone, free country, has the right and govern- ment alone should have the power put these one way doors the national economy. Doors that open wide let you but that won't open let you out. Fuehrer Lewis, himself just one 130 million other private citizens this country, seeks put one way door the coal industry and thus become its absolute dictator. Once inside that door, the coal miner must surrender his right free citizen change his mind under penalty being thrown out the window and never being able enter again. These one way doors shops” are portals labor slavery. They compel customers (union dues payers) keep buying prod- uct service (union leadership) regardless what happens its quality. And you want know how union leadership can deteriorate closed shop industry, visit the federal penitentiaries and look Scalise, Bioff and Browne. vital principle progress, well corner stone liberty, that any product service must sold merit and not bought under compulsion. might comfortable for THE IRON AGE its present readers and advertisers were compelled keep buying out busi- ness. But would hate think what might happen the editorial quality under such conditions. would nice the present customers steel company were prohibited, for perpetuity, from buying steel elsewhere, regardless whether that steel was good bad. But would unfortunate for the customers and the general public. Union membership that bought labor because sold through free acceptance superior service one thing. But one way door such Fuehrer Lewis would hang the portals great and vital industry anomaly this 20th century. | tely. ion” tical rents é | | | | | : —_" > — atl Helps Motorize America’s New Army Modern warfare calls for vast quantities high powered motorized equipment. That why factories throughout the land are working day and night supply America’s new army. with trucks, trailers, scout cars, staff cars and other essential vehicles. And for their construction Inland rolling thousands tons steel products— sheets and strip for frames, bodies, fenders, plates for axle bars for springs and bumpers. record pace Inland producing these and other products that the soldiers the may have the fine motorized equipment they require and deserve. Not only for army transport but for many other needs, Iniand men and mills are all-out for National Defense. Inland’s No. Job! INLAND STEEL CO. Dearborn Street Chicago, Illinois Sales Offices: Mi!waukee, Detroit, St. Paul, St. Kansas City, Cincinnati, New York SHEETS STRIP TIN PLATE BARS PLATES PLATE STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS propeller mount- for Curtiss controll- able hub for 1200- hp. engine. (McCauley Steel Propeller Co.) LUMINUM foremost materials for ap- plications involving defense equipment. fact, the moment, placed second the critical list, following magnesium. During the course this year increasingly strict control aluminum vari- ous forms has been exercised the OPM. consequence, its use for non-defense and unessential wholly, not entirely, stopped. Under OPM regulations the dis- tribution aluminum any form (ingot, scrap, semi-manufactured products, and finished goods) now governed priority control. present most the aluminum available being allocated effect, the aircraft industry and its sup- pliers for the production frames (with appurtenances) parts, and engines. Output military aircraft has ex- Conservation Aluminum panded rapidly the last year and the projected increase large that the demand for aluminum has threatened exceed the supply. Likewise, the diversion alumi- num aircraft and other direct applications for defense well essential indirect uses under the priorities system has forced its total elimination for numerous ci- vilian purposes. result, the country has been constrained adopt general program con- servation with respect this metal. Annual aluminum production today the rate 325,000 net tons; importa- tion from Canada runs the neighbor- nationwide aluminum scrap campaign last summer yielded about 5900 tons metal scrap which turn yielded approximately 3500 tons secondary the end 1942, planned that aluminum this country will reach pace about 729,000 tons annually, which time the government will own about per cent the All Europe 1937 produced approximately 380,000 tons Obviously, the available alumi- num supply may conserved for methods: First, decreasing the output non-defense products that require aluminum their manu- facture; second, its use for civilian purposes, and third, utilizing substitute materials. methods have been practiced this year. Thus, supplies producers consumers’ goods, for cooking utensil and radio manufac- turers, have been withheld reduced under OPM orders. cordingly, the output numerous items containing made alumi- num has been diminished vary- ing degree. Also, conservation measures involving the third meth- have been put into effect the Army, Navy, and industrial con- sumers. problem serious importance many manufacturing companies has been the necessity finding economic and technically suitable substitutes for aluminum without using other metals that also stand high the critical list. The gen- eral difficulty replacing alumi- num something else without in- crease cost impairment efficiency readily apparent since the accepted commercial applica- tions the metal have been de- veloped over period years THE IRON AGE, November 27, 1941—35 P i | f j 4 : ~ ee competitive basis against other materials. some cases solution has been arrived using cer- tain plastics that have been ad- vancing favor rapidly for dif- ferent purposes during late years. the other hand, various specialty concerns unable obtain aluminum have had curtail suspend pro- duction pending receipt defense orders, mainly sub-contracts, for articles adaptable their equip- ment. Others have been trying convert their plants new manu- factures. Under the exigencies the de- fense situation, has been neces- sary for industrial adopt materials other than alumi- num for many purposes connec- tion with war contracts, capital structures, and consumers’ Besides, numerous interesting sub- stitutions for aluminum have been devised the armed services order save this metal. Further investigations are being made both these groups determine how extensively various substitute ma- terials may utilized for standard applications. The magnitude this task can readily appreciated recalling that the individual uses now, approach 3000 number. Uses Aluminum undertaking conserve the the consumption for non-essential purposes, thus increasing the quan- tity available for defense, first necessary survey the whole field use and ascertain the numerous applications the metal. well known, aluminum and alumi- num-base manufactures sitions and forms. Thus, both the substantially pure metal and rela- tively impure aluminum are em- ployed for many purposes. Also, aluminum the main component light aluminum alloys and minor constituent various other alloys, both ferrous rous. Aluminum and its light alloys are marketed ingot, semi-finished manufactures wide range forms and sizes, and great diver- sity finished goods. Products that consist wholly major part aluminum are manufactured large quantities, and the metal its alloys may constitute small percentage weight various structures assemblies. Under war economy, substantial and immediate savings aluminum IRON AGE, November 27, can made prohibiting the application the metal for civilian goods that are normally produced large quantities. Aluminum cook- ing utensils exemplify use. Other important savings made restricting the utilization this metal for durable goods where may satisfactorily re- placed established competi- tive material. The use copper cars; electrical manufactures; pig- ment for paint, and radio appara- tus. the foregoing, the largest individual quantities aluminum were used the manufacture ‘able and cooking utensils. the period mentioned, other relatively important fields con- sumption were: Cans, boxes, and similar articles; refrigerating and air conditioning; gages and meters; Pyrex glassware saucepans. (Corning Glass transmission cables may cited example. Turning now brief consider- ation the main applications aluminum, may remarked that the five-year period 1935-1939, consumption the United States was mostly distributed among the following: Cables for the transmis- sion electric current; cooking utensils; motor vehicles (passenger cars, buses, and trucks); aircraft (including engines parts); general castings for numerous pur- poses; household uum cleaners, washing machines, and stamp- ing and fabricating for miscel- lany uses; metallurgy chiefly for deoxidation; machinery numerous kinds; building con- struction; foil and collapsible tubes processing equipment; boat building; bottle caps and clos- office and related light machinery; illumination (lighting fixtures and reflectors); and telegraph apparatus; screws, rivets, and the like; photographic equipment, and variety tech- nical instruments. Rather small trivial quantities aluminum have been used for numerous purposes including such diverse items poultry leg-bands, lithographic plates, undertakers’ supplies, hair- pins, printing ink, fans, wiring de- vices, beauty-shop equipment, mus- amount consumed annually minor applications has, however, been surprisingly large. Strangely enough, the number separate uses aluminum mili- tary equipment rather small al- though the total amount metai that may employed for direct defense purposes the United States the present emergency will likely enormous. The great — | production warplanes. Apart from aircraft, the principal mili- tary applications aluminum are for the following: Naval construc- tion; parts trucks, tanks, and ammunition carts; bomb and shell- fuse parts; flares; field mess kits and field ranges; pontoon bridges; gas masks; and some signal ap- paratus. Aluminum important the construction warships, be- ing used for bulkheads, doors, gal- ley equipment, and miscellaneous fittings. The primary object em- ploying aluminum here di- minish weight. Equipment carried the individual soldier should made aluminum other light material wherever such application practical. This also applies portable articles and mobile equip- ment general. Obviously, the re- duction dead weight very help- ful accelerating the movement men, guns, and supplies combat land sea well the air. After surveying the numerous determine which ones are re- garded non-essential and which are necessary for direct indirect purposes defense. The relative importance the various military applications matter consid- erable controversy. any rate, much aluminum has been made available for American defense OPM control which prohibits its unessential use. Substitute Materials Materials that may used in- stead aluminum for diverse pur- poses are rather numerous. How- ever, undertaking adopt particular substitute necessary consider several factors includ- ing its availability and cost well the nature the intended ap- plication. course, under free economy the commercial utilization materials mainly conditioned the circumstances competi- tion. Most frequently, therefore, the cost/utility ratio foremost importance. the other hand, under war economy ments for direct and indirect de- fense must take precedence over civilian needs. Accordingly, the quantities supplies have governed rationing and alloca- tions. Such controls force the un- economic use various materials for many commercial applications. first approach the prob- lem finding reasonably good, not wholly satisfactory, alternates note that with advances made over period years this metal itself has become substitute material wide adaptability. typical * airplane built molded plastic plywood. (Langley Aviation Corp.) examples practice serve re- flect the position. The aluminum- base products listed the follow- ing paragraph have been developed for use place the same ones manufactured the materials given parentheses: Paint (lead and zine com- pounds) electrical conductors (copper); structural shapes (steel and wood); foil collapsible tubes (lead and tin); building ma- terial (cement, stone, wood, and steel); ink black and motor pistons (cast iron) piping (brass); insulation (asbes- tos and magnesia) furniture (steel and wood); cooking utensils (cast iron, enameled steel and glass) artistic wares (copper and pew- ter); light reflectors (silver plat- ing); wrapping material (paper) and aircraft (wood). Many more instances might cited. Depending upon the application, either metals non-metals may used substitutes for aluminum. the metal group are included iron and ferrous alloys, together with non-ferrous metals and alloys. the non-metallic group are em- braced variety materials that may natural, processed, syn- thetic. The usual base metals and alloys thereof are adaptable alternates for use place aluminum its alloys. Whether cast wrought products are employed necessarily governed the par- ticular application. the ferrous class, plain carbon and alloy steels, iron various compositions and malleable iron are con- sidered. the non-ferrous class feasible substitutes may found among copper, lead, magnesium, nickel, tin and zine well alloys rich these metals. The specific compositions ferrous and non- ferrous alloys that may utilized instead aluminum-base materials need not examined detail here but require consideration together with careful scrutiny mechanical THE IRON AGE, November 27, | | | £ l- properties and other qualities order choose suitable substitutes. Numerous non-metallic materials may utilized place alumi- num for one purpose another. Most these have been common use for long periods time and far have been supplanted aluminum relatively small de- gree. Among them may men- tioned wood, concrete, minerals rocks, ceramic wares, ganic chemical compounds, textiles, various plastics, rubber and paper. Likewise, certain composite prod- ucts are adaptable for aluminum, for example lami- nated wood and steel coated with porcelain enamel. Rapid advances have been made late vears glass for structural purposes and plastics for use instead metals alloys many applications. New developments laminations, called, that layers wood paper bonded with stances, are increasing interest since these products are satisfac- tory substitutes for sheet metals different kinds structural assemblies. The substitution aluminum its alloys some other material may often involve merely simple replacement. Frequently, however, more less extensive changes the design parts, structures, machines are necessary when such substitution made. Fur- thermore, most cases alterations manufacturing tooling, other departures from established procedures are normally required. From the viewpoint conservation for defense in- advisable substitute for alumi- num material which likewise stands high the critical list which may shortly become critical. Rather, the attempt should made find something which avail- able plentiful supply. course, this has become increasingly diffi- cult, not impossible many in- stances, the course recent months. Specific Substitutions considering the preblem suitable alternates for aluminum and feasible substitutions prac- tice, remarked that there are sound utilitarian reasons for the use this metal all, almost all, commercial applications. rule, the adoption sub- stitute may expected result higher cost, decreased efficiency, inferior characteristics, some 38—THE IRON AGE, November 27, agitator for wash- ing machine. (Nineteen Hun- dred Corp.) other disadvantage. Hence, each separate case proposed substitu- tion will ordinarily require careful selection material order obtain the best, least ac- ceptable, compromise. The substitutions recently made for aluminum industrial consum- ers and the armed services are numerous that the confines space preclude giving detailed list here. (Furthermore, ities are under investigation.) Suf- fice say, however, that most the changes practice have been effected the fields non-essential articles and civilian goods. the same time, the consumption alu- minum for some strictly essential purposes has been diminished, for duction steel. Important uses that have been almost wholly elim- inated else substantially reduced are for cooking utensils, electric transmission lines, passenger motor ars, building construction, house- hold appliances various kinds, business machines, packaging, and radio sets. Ferrous alloys are being used place aluminum for variety purposes. Malleable iron suit- able substitute for cast aluminum alloys many applications but has the disadvantage weight. the field cast iron replacing aluminum alloys for pistons, cylinder heads, and other parts passenger car motors. Steel sheet widely applicable alternate for aluminum and its alloys general forming and stamping. Owing its relatively high content chromium and nickel, stainless steel (18-8) critical material but such ranks lower than aluminum the OPM list. Notable advances are being made the use stainless steel for aircraft construction.* For ex- Within year Edward Budd Co., William Stout and others hope making very large cargo aircraft en- tirely stainless. See THE IRON AGE, Oct. 30, 62, Nov. 93.—ED. ample, the new Fleetwings BT-12 basic trainer built largely this alloy. Also, steel propellers for airplanes are finding increased application. high-strength alloy steels were utilized more extensive- for aircraft, less aluminum would needed that field and larger supply the latter metal could made available for other important defense purposes. Plain, tinned, and porcelain enameled steel, cast iron, and glass are the accepted ma- terials for use replacement aluminum for cooking utensils. Substitutions for other non-ferrous base metals have not been numerous the ferrous materials since supplies copper, lead, magnesium, nickel, and zine are all below anticipated re- quirements. matter fact, much work has been done both industrial consumers and the armed services develop suitable substitutes for the several non- ferrous metals. The bulk placement has been made ferrous alloys and non-metallic substances. result increased demand for these, shortages have already ap- peared some lines, including foundry iron and plastics. Lead had been fairly ample supply un- til recently. Accordingly, paints were being used place aluminum paint and lead foil substitute for aluminum foil. How- ever, lead has now been placed un- der full priority control and alter- nates for are being sought. Clearly enough, the business forcing demand from aluminum some other material may soon cause shortage the latter. Passing now the application non-metallic substances place aluminum, may noted that plastics have been employed rather widely for Thus, plastics are being utilized substitutes for aluminum parts household equipment, including washing machines, vacuum cleaners, refrigerators, and utensils. Plas- tics are likewise used food service trays, handles and knobs many kinds, phonograph- tone arms, variety housings, lighting reflectors, and parts fruit-juice extractors, scientific in- struments, air conditioning equip- ment, and business machines. Plas- tic airplane parts have been adopt- ed, and entire planes (fuselage, wings and controls) have recently been laminated wood, bond- with plastic material. Glass has appreciable possibilities substitute for aluminum, for example sundry household appli- ances including cooking utensils, refrigerators, and stoves. Prob- ably the best known applications glass place aluminum are for cooking utensils and structural material building. Paper and cellophane are used instead alu- minum foil for packaging food. Wood replacing both steel and aluminum for office furniture. Economic Effects the result forced volun- tary conservation measures re- spect aluminum sundry serious effects have appeared the na- tional economy. These include the shutdown curtailment plant migration labor, decrease gross business merchants, temporary, and perhaps, permanent loss refrigerator which several aluminum parts have been replaced porcelain enameled markets for various alu- minum products, reduced output civilian goods, and other dislocations. the same time the di- version aluminum defense purposes has has- tened the large new aircraft plants, driven many companies into unfamiliar branches manufacture, and spurred investigation search for substitute ma- terials. addition, lack aluminum has impelled managements study the possibilities making new products from ma- terials that are likely continue large supply and free tions. The impact the de- fense program concerns aluminum has been dis- astrous the case relatively small firms the cooking utensi! and tries. This also applies general small alumi- panies. Large manufac- turers civilian goods, including makers refrigerators and some other durable semi-durable prod- ucts, have been able develop sub- stitutes for both aluminum and other non-ferrous metals. known, many little the metal stamping and fabricating field need get defense orders the earliest possible date order survive and provide employment communities. This true especially manufacturers parts for household appliances, radios, and motor vehicles well small stamping and other shops that are equipped work various metals. Numerous substitutions for alu- minum, both metals and non- metallic substances, are doubtless temporary nature, that for the duration the emergency. lowing for inertia making the change back again, the common out- lets for aluminum will likely re- gained due course after the metal once more available ample supply for non-defense uses. Note may made the way that specifications for various alu- minum-base products have been re- laxed different consumers includ- steel. (General Electric ing the armed services permit the use secondary metal where was formerly excluded favor primary aluminum. this connection emphasis placed upon mechanical physical prop- erties and performance applica- tion rather than chemical composi- tion. Moreover, rather low grades secondary aluminum are being admitted for some purposes. related the matter re- search developing suitable sub- stitutes for aluminum, may remarked that advantage being taken the present opportunity producers tutes, processed materials and synthetics generally explore the possibilities with the view ex- panding their markets. Numerous ingenious applications the sub- stitutional field have been brought forth and more are expected the emergency continues. The stimulation research least one worth while by-product the war. Supplies Set Record During the last year, much has been heard about shortages alu- minum and other ma- terials, although prac- tically all cases the out- puts supplies are the largest record. Defi- ciencies quantities for all purposes ascribed part errone- ous estimates total re- quirements and part unexpected increases for planation inadequate supplies the case aluminum any other metal not hard find. all, nearly all, alumi- num available set aside for the construction aircraft, and still more wanted for that purpose, there scarcely going any left for any other use. Obviously, the solu- tion the general prob- lem so-called shortages allocating creasing output and im- ports, utilizing suitable substitutes for both air- craft and other applica- tions, and reducing the consumption for non-es- sential goods. THE IRON AGE, November 27, {S to 'S f e | Measuring the Fluidity Cast Steel ° HOWARD TAYLOR Associate Metallurgist and ° EDWARD ROMINSKI Assistant Metallurgist, Naval Research Laboratory Anacostia Station, Washington, (Published Permission the Navy Department) simple, quick, yet adequately sensitive, technique for measuring fluidity described herein. Molds for use with both lip and bottom pour ladles are discussed and the effect sand, pouring heights and other test vari- ables are noted. quire not orly that compo- sition held rigid specifications, but also that fluidity (variously termed castability, life, life, runability shankability) must such that the molds will readily and satisfactorily filled. castings, lapped surfaces and un- faithful can often laid directly the slug- gishness the steel used for pour- ing. Badly skulled ladles are not uncommon problem, and has been suggested from time time that the efficiency risers, center line weakness, resistance hot tearing and similar characteristics may influenced the fluidity the casting metal. obtain the best 40—THE IRON AGE, November 27, With this mind, the Naval Re- search Laboratory here undertook develop mold and technique suitable for measuring the flowing quality steel the furnace order determine the proper tap- ping time. The laboratory also sought develop modification this test enable foundrymen determine the fluidity the steel the ladle any particular time. What was sought this investi- gation was test piece which should capable measuring accurately small variations fluidity and yet faithfully evaluating maximum and minimum values which result from extreme conditions temperature and composition. Too, the test mold should simple, inexpensive make and convenient prepare, easy manipulate and read di- Cast steel fluidity test piece. rectly. Accurate leveling should not necessary and provision should made for maintenance con- stant flow head least one which varied within narrow limits. Finally, results from the test piece should reproducible. The spiral type test piece for measuring the fluidity cast metals was proposed early 1919, but remained for Saeger and Krynitsky the National Bureau Standards, adapt for use with cast iron and non-ferrous metals. The work was published 1936 and later this test became A.S.T.M. standard for measuring the fluidity these metals. Previous Experiments Several attempts have been re- corded where spiral flow channel has been tried with cast steel but little success was reported. Some time prior 1936, Ruff found the spiral not fully satisfactory and concluded that dynamic laws ap- plied more directly when straight flow channels were cordingly, developed test for use measuring the fluidity a * J | | ° | | | ‘ast steel which involved straight cylindrical flow channel 3/16-in. diameter fed through simple conical runner. all tests dis- cussed, the flow channel was made sand molds either the green air dried type. The straight flow channel has been used extensively England for both research and plant testing and some extent America. Opinion varies widely the this method testing for routine tice. Kron and Lorig, working Bat- telle Memorial Institute, published the results work the subject 1940. They used straight flow channels, 7/32-in. diameter, and their mold was improvement over that Ruff because the in- clusion the design carefully controlled ferrostatic head which governed the entry metal into the flow channel. From careful study the re- sults obtained the various in- vestigators using the straight flow channel, was apparent that this type offered little promise foundry tool. Test values were not dependable and lengths flow were very short. However, several tests were made the Naval Research Laboratory before this type was type. The results preliminary tests the laboratory indicated that the Ruff mold, unless provided with means for controlling the ferro- static head and regulating the flow metal, did not give consistently mental points were badly scattered. The tests also showed that the 3/16-in. diameter failed give significant lengths flow steels which were still fluid enough fill mold. The maxi- mum lengths flow for steel average analysis normal pouring temperature were than inches. was impossible, this size channel, accurately measure small variations fluidity. was also found that the mold employing straight flow channel recuired careful leveling before pouring. Because the success reported when Saeger and Krynitsky used the spiral mold for measuring the fluidity cast iron, this type offered more promise test for cast steel. Accordingly, this type was next tried, and after the modi- fications necessary adapt steel, satisfactory test was de- veloped. The details the final de- sign are given Fig. and steps preparing test mold are shown Fig. Fig. shows the arrange- ment test mold. order standardize the meth- od, however, was necessary determine the influence variables, effect sand grain size, green, dry, and cement sand, pouring height, and the case tests the arc furnace, determine the effect time holding the sample the spoon before pouring and determine the amount aluminum added the spoon sample. The results such tests were found necessary evaluate these variables are summarized below. Summary Investigations Nearly all the development work was done using in- duction furnace, melting and sampling were greatly simplified and results were fully applicable though all tests had been made spoon samples taken from the are furnace. From the results this work the following conclusions may drawn: (a) The spiral test piece, finally adopted, upward from end Cross-section area »04 Section B-B \ \ Section A-A details spiral fluidity test pattern found most Fluidity spiral Straight downgate type with modified pouring basin for evaluating the fluidity cast steel. Results are reproducible, and the mold simple and con- venient prepare. Reference marks the cope surface the casting make read directly. (b) Variations sand grain size from fineness number 123 showed selective in- fluence casting length. Molds made bentonite bonded green and dried sand, and cement sand, when poured under identical conditions, gave lengths. Thus the test not sensitive any normal differ- ences the various molding practices and results foundries would comparable. (c) Within reasonable limits (variations from in. above the pouring basin) pouring height did not affect the reproducibility the test. (d) Varying the amount alu- minum added spoon samples taken from the are fur- nace indicated that 0.4 oz. (strip 3/16 in. 1/16 in. in. long) was the proper amount for average heats plain carbon (0.15 0.30 per cent steel the unkilled condition. (e) testing the are fur- reference satisfactory for half-ton smaller ladles. THE IRON AGE, November 27, ° a < ° j \ \ \ \ \ 15° Ay nace the time normally pour the fluidity test casting from the instant dipping about sec. determine what variation might exist the speed the operator varied from plant plant, tests were made which proved that was possible hold the metal well slagged spoon long sec. without invalidating the results the test. Composition has marked influence fluidity, the magni- tude varying with the nature and amount the alloying element. The state oxidation the bath major factor governing fluidity. Results indicated that POURING RUNNER mold (shown Fig. 2), the steel poured into the runner guide, builds the lower overflow level, runs into pouring button and hence into the spiral. second overflow trough, in. higher than the first, empties into catch basin. This arrangement prevents the fer- rostatic head from changing more than about in. and provides smooth flow metal into the spiral. completely filled casting weighs lb. when the overflow basin filled. The usual test weight, how- completely fill the overflow. The testing technique adopted standard practice for Overflow trough Pouring runner basin we// button MOLD ASSEMBLY assembly spiral test pattern shown Fig. and details pouring runner. critical amount deoxidation was essential maximum flow. Variations above below this value resulted shorter spiral lengths for any given tempera- ture. The temperature the steel was found have pre- dominant influence casting length. The relationship for ordi- nary analyses not function the temperature in- creases from 2732 deg. 3092 deg. 1700 deg. The in- crease test casting lengths re- sulting from increment temperature change decreases the higher temperatures. Preparing Test Molds Ordinary molding technique used preparing the molds and the molds may either green dried sand. dry cement sand the molds assembled prevent fins which would otherwise lead poor results. making tests with this 42—THE IRON AGE, November 27, use with the laboratory one-half ton, three-phase furnace has proved very satisfactory. The mold placed position near the fur- nace door. The sampling spoon holds about steel and ft. long. coil aluminum 3/16 in. 1/16 in. in. long wound the end small rod also re- quired. These are all requirements for the test. Whenever test desired, the operator warms the spoon and slags carefully. The sample taken point near the center the bath possible and quickly drawn from the furnace. the spoon crosses the door sill, second operator vigorously stirs small spiral aluminum for deoxi- dization. does this while the man handling the spoon moving into pouring position and does not inter- fere with the test. The spoon then dumped without loss time into the runner guide. has not been found necessary slag the sample the spoon but this may done desired. The spiral immediately solidifies and can shaken out the mold and its length observed. The ref- erence marks the cope surface the spiral are in. apart and facil- itate reading the length flow which taken the index fluid- The aluminum only needs used for tests prior final addi- tion when necessary insure killed sample, but long standard practice observed will times. Tests Prove Advantageous From routine use this test all heats made the laboratory are furnace, definite advantages better steel and cleaner ladles have resulted. Not only has been pos- sible follow the progress the heat determine the proper tap- ping time, but has been possible determine the effects changes slag charging practice, alloy- ing elements, and type, amount, time, and order adding deoxid- izers. Rapid changes fluidity result suddenly increased decreased power input can read- ily detected. For example, one test was made relatively cold steel giving spiral length in. subsequent test taken min. later while the power had been raised sharply gave in. Tests taken before and after final manganese additions gave in. and in., respectively, whereas tests three minutes later, before and after final silicon addi- tions, gave in. and in., re- spectively. Fluidity was greatly im- proved the addition silicon but was not changed the man- ganese. One series tests involved mea- surements the furnace the pouring floor. Just be- fore adding the final additions manganese and silicon the length spiral was and in. two tests. Following the addition the flow increased and in. this point the bath was rabbled and tapped and optical pyrometer readings indicated the temperature capacity teapot ladle mold was poured taking about 300 metal. Next two fluidity test pieces were poured and flow had fallen and 16% in. result heat loss the ladle and atmos- phere, the temperature indicated 2730 deg. | Two more large castings were poured then three spirals were poured order one minute in- tervais. Oniy amount metal was lett the ladle and tem- perature was falling rapidly. The casting lengths were 14, and in. the respective pouring order. The temperature was esti- mated quick pyrometer readings about 2680 deg. for the last mold. was found possible, associating the length spiral obtained the furnace before tap- ping with the manner which the steel handled the pouring floor and with the quality castings ob- tained, predict the casting be- havior any heat steel. Spiral lengths least in. are re- quired before the addition final deoxidizers the practice the Naval Research Laboratory. This usually results spiral length in. just prior tapping. Thirty-two in. final fluidity recommended for larger heats where more molds must poured. Following the satisfactory ap- plication the spiral mold for fluidity measurements the half- ton furnace the Naval Research Laboratory, tests were made using the three-ton furnace the Wash- ington Navy Yard. this case removal the sample was thought complicated the more in- tense heat from the larger door opening and the greater distance the center the bath. Plan- ning for this, larger and heavier spoon was welded diam- eter iron bar about ft. long. pipe section ft. long welded the bar give over- all length slightly greater than ft. without unnecessary weight. The heavy iron bar was necessary prevent bending from the weight sample when the rod heated near the spoon. The technique for handling this sampling spoon the same for the smaller one used the half-ton furnace except that drawn from the furnace, two extra men are needed sup- port the sample and move into position for pouring. This done means cross bar slipped under the rod any convenient point between the sample and the operator. Several satisfactory tests were made this way, but was later found that sampling could done with the smaller spoon which re- quires only single operator. larger furnaces, however, might impossible and the use RAG sec- tion, showing blind reservoir. OPE section with pouring basin pattern place. Note raised reference marks. OMPLETED mold, ready for closing. SSEMBLED and clamp- mold, ready for pouring. * \ THE IRON AGE, November 27, Fig. 2—S ing Mold ig. 2—Steps Preparing Test Mold. yx ° ° ° | ~ x * ° ° ° J the larger spoon would sary. The total time for making the complete test well under min. the use four men (three handle the spoon and one stir ing factor. Results obtained from this work the Washington Navy Yard are few because the method has only been tried for short time. Tests taken before and after final de- oxidizing additions the furnace gave and in. flow respec- tively plain carbon heat approximately 0.20 per cent carbon. nickel steel heat from which spiral was poured just before tap- ping gave in. flow. This steel was known more fluid than plain carbon steels because the presence per cent nickel. Large Test Piece The small mold previously de- scribed satisfactory for half-ton smaller ladles, but unsatisfac- tory for larger bottom pouring ladles because the rapid rate flow steel from the nozzle. the request the Norfolk Navy Yard for method measuring fluidity cast steel under these the test piece was designed. This merely large scale modification the smaller fluidity test mold. Principles flow are identical and measurements made the appro- priate use either test are com- parable. The molds can made green sand desired, but dry sand preferable when they are allowed stand unused for more than few hours. Ordinary molding meth- ods are used and the effects variables are the same for the small mold. The Norfolk Navy Yard made the mold cores, thus obviating the necessity for flask, and molds were made and stored for use needed. When making test the ladle nozzle centered above the pour- ing reservoir and the mold filled ordinary rate. The metal builds the level the overflow into the pouring button and fills the spiral under conditions free from turbulence possible. The overflow trough 0.25 in. higher than the first and about this amount. soon the metal starts flow into the over- flow reservoir observer calls “full” and pouring stopped quickly possible. metal should build above the level the 44—THE IRON AGE, November 27, overflow, the value the con- trolled head would lessened and would harder shake the test casting from the mold than wouid the case pouring were stopped rapidly enough prevent any metal being left the slanting overflow. Tests were made the Washing- ton Navy Yard and was found plate front the overflow into the spiral prevent meta! splash- ing spurting prematurely into the flow channel and interfering with normal flow. This baffle also serves skim gate keep slag dross from getting into the test channel. runner guide always used. After providing the baffle core, series tests was made the Washington Navy which proved the test piece satisfac- tory. Six dry sand molds were pre- pared and placed position the foundry floor. Small castings were being poured and several openings were necessary that there was large drop the temperature the steel between the beginning and end pouring. 10-ton ladle was used and after first pouring large mold heat the nozzle, two test castings were poured. These measured and in. After metal the ladle had been poured into nine molds, the second pair tests was taken. Only one spiral filled this test sand had clogged the flow channel but the geod spiral measured in. After pouring nearly all the remaining metal into molds, the final pair tests mea- sured and in. the order poured. These tests, well one more series which results, established the spiral mold satisfactory for measuring the fluidity cast stee! the foundry floor. Tests Practical Value impossible list all applica- tions for this type testing they depend largely upon the in- dividual foundry. For example, small casting producer would only concerned with the fluidity test the furnace while the heavy cast- ing manufacturer would also in- terested the condition the metal the time pouring. taking tests before, before and after, pouring large casting, would possible tell the effect fluidity such factors hot- tear, center-line weakness, etc. aggravated conditions the cooled casting could associated with the fluidity the steel used, many current founding problems would explained and the foundry- man possibly provided with means for their solution. might prove practical mark clearly the pat- tern the spiral lengths the metal used for pouring particular casting. This would facilitate the manufacture castings ordered from this pattern some later date when the foundry details had been torgotten. From the large number tests conducted with the smaller fluidity mold and from the comparatively few trials made with the large type, several advantages can claimed for the spiral effective me- dium for measuring the fluidity cast steel. The mold convenient prepare, economical, direct reading, and compact, and results obtained from its use are highly reproducible. leveling necessary and the design the flow channel such that factorily indicate small variations the fluidity the steel. Provision made for in. flow, and while this length sel- dom reached (never for plain car- bon steels temperatures below 3092 deg. F.) the difference flow between extremely low tempera- tures and high temperatures be- tween very sluggish and very fluid steels ample for testing under the most extreme conditions normal- encountered. For given steel analysis and shop practice, would possible calibrate the spiral directly temperature units with probable accuracy deg. (77 deg. F.). Such calibration would have maintained the steel bath and pouring spirals small increments temperature. date refrac- tory available which can used sheath for protecting thermo- couples from the corrosive action basic slags and temperature mea- surements this way are extreme- troublesome. Acid slags present unusual difficulty, however, when quartz used protecting sheath. Since temperature always true criterion the cast- ing quality steel, sole reliance this quantity would many times misleading. The valuable calibration would terms results obtained the pouring floor. | HIS paper presents simple method determining quan- titatively the effect hydro- gen embrittlement produced commercial cleaning solutions. And, various curves and data show the effect heat treat- ment the susceptibility em- brittlement several different steels. Drawing temperature, hard- ness, section, and chemistry affects hardness, are found