The Iron Age 1942-01-01: Vol 149 Iss 1

- SKINS PRODUCTS HEAT TREATING FURNACES ELEMENT ALLOYS THERMOCOUPLE AND THE IRON AGE, published every Thursday the CHILTON second class matter November 1932, the Post Office Philadelphia under act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 149, No. has muffle; units radiate heat directly onto the work. This plus the ample input results very recovery JANUARY 1942 VOL. 149, 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 : W. A. PHAIR T. —E. LLOYD 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 Birminaham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis Newark, ° ° DIX, Manager Reader Service ° ° Advertising Er Herman, Chilton Bldq., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Leonard, 100 East 42nd New York Pei Lewis, 7310 Woodward Detroit Ober, 100 East 42nd St., New York Robinson 428 Park Bldg., Pittsburgh Warren, Box 81, Hartford, Conn. Johnson, Market Research Mar. Hayes, Production Manager. Baur, Typography and Layout. ° Member, Audit Bureau Circulation Member, Associated Business Papers ndexed the Industrial Arts Index. Pub shed every Thursday. Subscription Price United Stafes and Possessions, Mexico, Cubo, and South America, Canada, Foreign, $12.00 year. Single copy, cents. ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and 5éth Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GRIFFITHS Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE THE Editorial Let Resolve— Annual Review Features Challenge the Metal Industry Expansion Uncertainties Plague Washington Lineup Armor Tons Jewelry Steel Fight for Problem Metal Working Groups Face Survival Test Detroit Transition Machine Tools Behind the War Metallurgy Fights Two Fronts Non-Ferrous Metals War Metal Industry Price Ceilings The Iron Age Statistical Section Features Assembly Line Washington The West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Special Advertising Sections Steel Mill Metal Treating and Finishing Machine Tools and Small Tools Pressing, Forming and Welding Accessory Equipment and Parts Products Advertised Index Advertisers Copyright, 1942, by Chilton Company (inc.) Eighty-Sixth Annual Review Issue | | 121 218 222 Beginning the 100th Year Steel-Service Large and complete stocks, steel known quality, RYERSON STOCKS prompt and dependabie service....these are the Beams and Heavy Structurals rugged cornerstones which the Ryerson business has been built. 100 years experience the Rails, Spikes, Bolts, etc. Plates and Sheets disposal Ryerson customers help them meet Hot Rolled Bars, Hoops and Bands every steel problem. Today, our stock many lines depleted and war needs have the right way. Heat Treated Alloy Steels However, continue serve every customer the Stainless Steel best our ability accordance with the Govern- ment Program. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Concrete Reinforcing Bars Babbitt Metal and Solder Cleveland, Buffalo, Boston, Philadelphia, Jersey City. RYERSON 44—THE IRON AGE, January 1942 | JANUARY 1942 ESTABLISHED 1855 ° Let HEY said that America had become decadent and soft. They said that loved comfort more than principle; that lacked the guts our grandfathers. They said that our manufacturers put profits above patriotism; that our workers lacked sense civic responsibility and were interested solely exacting the last farthing. They said that our Democratic way life was done; that our legis- lators had become opportunists and practitioners expediency; that were being ruled and ruined gangsters and racketeers. They said that America fight. And then came Colin Kelly, Jr. And those miasmic mists doubt one another vanished the bright sunlight heroism. Captain Kelly had much live for. beautiful wife and year- old son meant much the future this 26-year-old father any future means him. Life sweet, 26, when you have these come home to. But Captain Kelly did not come home. gave all that had his country. Captain Kelly sank, singlehanded, enemy battleship. died line duty his country. But sinking that battleship was not the greatest thing that Captain Kelly did for his fellow Americans. Beyond and above that was the fire that kindled the souls his countrymen. taught us, others like him are continuing teach us, that the red blood heroism still courses through American veins. That are not soft decadent people but that we, like him, can will—and will— subjugate all self interest the service our country. say you, whatever your position life your occupation, remember Captain Kelly. And resolve emulate his fine devotion his country. Perhaps you will not, like him, have the honor dying for it. But you can live for similar heroic fashion. you are employer, think Captain Kelly when self interest conflict with service your country and our common cause. And resolve act you know would have, were the one make the decision. you are worker, think Captain Kelly you run your machine assemble your product and give all that you the vital task arming his comrades. you are statesman, let the shadow Captain Kelly fall upon your shoulder you vote upon legislation, and you will fearlessly legislate for all America just died for every American. know better New resolution. | | : q +y | ® | 3 q - 7 ae hee. — A Kansas City, Cincinnati, New York RCING 942 0. i Fou e Rig bad Le 29 Te 2e, ° Our tals ERHAPS some future Gib- registering the crimes, follies and misfortunes man- kind, the year 1941 will nothing more than sharp little jiggle the curve charting the queer course human destiny. But the little man that year—the guy who works, votes, occasionally prays and always pays—it was momentous year great activity and bitter confusion, taking exorbitant toll energy and probing his most sensitive economic and sociological nerves. Why this activity, tension and confusion? Hitler decade ago said that they would the symp- toms “the last disgusting death rattle corrupt and outworn (democratic) system.” But hoped that history will show them rather disconcerting birth pangs initiating tremendous in- dustrial effort somewhat effete democracy none too confident its “rendezvous with destiny.” Quite obviously the core this industrial effort has been the metals industry, and has reeled all year under the impact goodly portion the activity, tension confusion. Every decision, mistake and tri- umph has been the subject close scrutiny and comment bevy opinionists, analysts and impres- sionists—all quite understandable view the quite obvious fact that this second world war con- flict metals and whereas the first world war could 48—THE IRON AGE, January 1942 perhaps called conflict chem- istry, and all previous wars clash- ing manpower. Very early 1941, when the fingers the somber shadow all- out war were only beginning close in, the ever-smoldering schizo- phrenia the American people flamed with startling abruptness. The nation’s youth flooded into Army camps and matrons Fifth Avenue slugged their way savagely silk stocking counters. And the industrial front was dif- ferent. Billions dollars were hastily dumped into prises, while innumerable metal consuming plants worked extra shifts hitherto unprecedented pace—not implements war, but conventional consumer goods; consumer goods meet spectacular nation-wide buying spree and amass impressive fu- tures warehouse shelves. The impact all this was too concentrated, even for the much- vaunted American industrial sys- tem that flag wavers are prone flaunt smugly before the world. Something had crack. Something did crack. first, crescendo, then mid-year fortissimo, were the cries makers civilian goods, metal shortages developed. April came pinch aluminum, magnesium, copper, nickel and other non-ferrous metals, then steel shortages September. Just might expected, the most pitiful laments frequently came from those companies least hurt. And, while the cruel farce sub-contracting was cynically played well lit stage, the wings many small manufacturer consumer goods patiently sickened died with the fortitude and lack display which always typical the poor the small. Beset mounting manufactur- ing problems, distrustful and baf- fled Washington, bedeviled labor disputes, rushed along full flood events leading into un- familiar and distressing political and sociological territory, the metals industry during the year dug and, did re- markable job production. also cursed Roosevelt, went after each others’ customers with renewed vigor, kept fairly sharp eye selfish interests and, occasion torment, lashed viciously min- utiae. With little investiga- tion and even understanding, bitter barbs were leveled En- gland for “selling lease-lend steel South America,” for selling comparatively infinitesimal quan- tities metal products this country, against Canada for selling die castings the Detroit area, etc., etc. Only serious indus- trial repression and abject crawl- ing, particularly the part En- gland, served appease the blind wraths. And England, while there thankfulness for American aid, there certain amount ¢ | § | 1941... acrimonious talk the sinister de- signs American producers British export markets, and cer- tain amount wonder how they will live after the war over. But for ignorance and infantilism, manifest its most vicious form, probably nothing will ever quite approach Senator Nye enthralling wildly cheering audience with bitter condemnation the govern- ment for permitting Navy Yard sell monthly scrap list alu- minum while the house-to-house aluminum begging campaign was progress; Senator Wheeler wav- ing fistful toy lead soldiers the Senate during one the most critical periods the Nation’s history, crying meanwhile, “here are British Redcoats made lead sent over here when the United States are told that use lead must curtailed because defense. Why are these little toy soldiers here?” The aberrations Senators Nye and Wheeler are, course, only several many examples the ridiculous conception the prob- lems metals 1941. But, just one step above the ridiculous the sublime, and sublime ineptitude about the kindest way certain ac- tivities OPM 1941 can de- scribed. Granted, course, that OPM staffed with many sincere men, some instances with bril- liant men, and also granted that the metals industry 1941 was in- volved such train unforeseen and unsupposed circumstances that human wisdom could accurately calculate the end. Nonetheless, the policy has been insist square pegs round holes; hav- ing man who knows nothing about particular metal rule that metal; sending plumber fix watch. This policy apparently stems right back President Roosevelt. The result all this has been primarily one jackassing more capacity —of substituting capacity for ex- perience industry—of solving the day-to-day problems par- ticular metal half measures One full year mournful errors, mean politics, humble cares, fears, fleers and jeers. year hard work, flim-flam stories, phrase monger- ing, and futile speeches. year wherein the world's greatest metal-working potential ner- vously started work formidable momen- tum that may yet lift tormented world off ° its hinges. ° LIPPERT Managing Editor, The Iron Age ° letting them degenerate chaos. Even today, with the country war, there has been little ele- vation men with knowledge authority that metal, the result being that certain industrial ex- cesses and selfish practices continue, certain half measures falter along, and large quantities metal lie idle while machines war wait. This all translates the possibility American soldiers may wait vain for 100 more airplanes 1000 more rounds ammunition—air- planes and ammunition that could have been there, if! Take, for instance, copper and zinc, two metals which very early went under full priority control. First, fearing shortage zinc, industry was urged switch from ° brasses bronzes silicon bronzes, then six months there has been complete reversal, and the urge now switch back brasses save copper. With centralized control zinc consump- tion, one agency the government would demand that galvanizers re- duce consumption, that steel painted rather than galvanized. the same time another agency would recklessly ordering prime gal- vanized sheets for bins, roof- ing multitude other uses where either wood uncoated steel would have been satisfactory. Table shows that plenty the galvan- ized steel output 1941 went into usual consumption channels having connection with the war effort. present believed there will enough zinc for essential needs. Now the government fears copper One generation's waste another generation's gain. This separating unif South Chicago working old slag dump recover upwards per cent the metallics contained therein. THE IRON AGE, January 1942—49 ° | | ‘ h r a 4 4 ir e- | 3 ile q § MILLIONS NET TONS Inauguration teel and auto strikes declared Nar Say unec Government steel capacity onomically hig TABLE Distribution Steel Shipments, All Steel Ingots, RAILS HOT ROLLED BARS Billets, and Finished and Wire Rounds, Shapes including including Concrete (Carbon Pipe including Sheetand and Over All Track Hoops Rein- and Wire Fence Black Tin Bars Piling Ib. Other and Binds forcing Alloy) Tubes Rods 72,290) 105, 493 142, 500 3,532) 320 75,397 36,348 23,700 6,485) 183 279 ,637 3,138) 10,320 18,258 180 1,622 9,600) 4,342 116 Other 2,290 11,970) 12,925) 544 1,466 78,146) 4,591 2,683) 9,262 Warehouses........ 2,414 13,725) 190 1,050) 1,291) 60,770 11,420) 3,564) 2,888 7,846 1,930) 1,970) 330 2.791 3,552 2,381) 660 1,195 TABLE Distribution Total Unfilled Orders and Commitments Ingots, RAILS HOT ROLLED BARS Billets, and Trade Finished and Wire Classification Slabs, Tube Structural| Plates Carbon Bars Products Rounds, Shapes (Universal including including Concrete (Carbon Pipe including Sheet and and and Over All Track Hoops and and Wire Fence Black Tin Bars Piling Sheared) Ib. Other Spikes forcing Alloy Alloy) Tubes Rods Posts Plate 1,314,754 17,545) 99,145 341| 4,512 21,406 21,873 687 *Based figures released Department Commerce figures, individual reports, and the author. Stainless steel, and furnace and open hearth alloy steel. 50—THE IRON AGE, January UNFILLED ORDERS AND COMMITMENTS, ALL STEEL PRODUCERS 1937 1941 Roosevelt Carnegie 1941 Tried the Steel Maker’s Soul And here why! Total finished steel backlog for the entire industry meanders along through the relative pros- perity 1937 and the doldrums and only spurt dizzy pace Late 1941 the crush SPAB approves Hauck’s 10,000,000 ton expansion program Break caused ruling that customers must file Form PD-73 with steel orders orders had the industry pretty well rocked back its Second Gan Dunn Report “Capacity not heels, and only the wiping out duplicate orders and overbuying means form PD-73 served stabilize promise sheets. The capable way the industry performed Capacity adequate” mitments already listed books for 1942 are shown below Table Il. Data for the backlog graph were secured from steel makers having per cent the country's capacity, con- verted 100 per cent with proper consideration car- bon and alloy balance. Data Tables and came from early AIS estimates, Department Commerce, various private reports, and estimates author from information supplied several major producers. Some minor errors are probably due diversity information sources. The Iron Age 1941 ° ° Producers, for Month December,* 1941 (In Net Tons) SHEETS AND STRIP TOTAL All Steel Producers,* Jan. 1942 (In Net and Cold Hot Cold All Steet and and All Steel All i | | | | THE IRON AGE, January £ ; Rooseve will be Dem ¥ eel late 183 581 116 262 nts 958 5,378 20,778 y steel, TABLE Distribution Industries (1929, 1937 1941) (In Net Tons and Per Cent Total) 1929 Tons Percent Agriculture. 3,060,960 (a) 7,352,800 16.0 Construction 8,643,040 18.8 Furniture, furnishings 700,000 1.5 Machinery, tools 2,028,320 4.4 17.7 2,495,360 5.4 7,179,666 15.6 45,997,746 100% 1937 1938 1939 2,335,200 5.7 1,420,697 (a) (a) 7,814,240 18.9 4,053,280 17.2 5,906,358 6,037,920 14.7 4,398,240 18.7 6,100,386 3,218,880 2,136,960 9.1 2,978,463 1,494,080 3.6 868,000 3.7 1,182,235 1,804,320 4.4 831,040 3.5 1,460,000 3,034,080 7.4 1,820,000 7.7 1,841,599 (c) (c) 659,864 11.4 1,443,680 6.1 3,250,022 390,880 0.9 389,760 1.7 517,771 3,032,960 7.4 1,752,800 7.4 2,594,700 7,329,716 17.8 4,765,271 20.2 11,155,458 41,178,356 23,568,951 100% NOTE: Distribution 1929 1938 Worthing, based data from The Age: 1939 1941 from The Age, various reports, and estimates, with jobber tonnage distrib- uted and other alterations made according the technique devised Worthing. shortage sufficient interfere with the 600,000 tons cartridge brass planned for 1942. stop-gap use steel for cases has been iously devised metallurgists take some the slack, some 500,000 tons copper per brought from Chile—and, then, few weeks ago, the country was flabbergasted the news that do- mestic copper mines and refineries have been ambling along 40-hr. week. And one seems give much damn about the large volume domestic marginal pro- duction available. Also, copper and brass mills have usually found satisfactory cast billets for subsequent rolling. Now enormous extrusion presses (the government pays for them) are built and a-building extrude bil- lets for subsequent rolling. early OPM order tied all use sec- ondary copper while the same time various war industries still in- sist brasses and bronzes low lead that scrap copper must involved the rank waste go- ing back through the refinery. Sec- ondary firms are today glutted with copper and can’t sell it. Even just little intelligent effort could force all the secondary metal into cer- tain applications that have been and are today absorbing large ton- nages virgin copper, thereby re- leasing the latter for war work that currently marking time. aluminum, too, the govern- ment has been engrossed giv- ing the industry public hot-foot that the problem secondary metal cries vain for attention—a sit- uation that both tragic and baf- fling. Right today there one authority Washington who 52—THE IRON AGE, January 1942 48,660,369 knows the intricacies the alu- minum industry. the moment there peak stock aircraft this has lulled many into false sense security. But, mid-1942 some large aircraft assembly units will swinging into production, for instance Ford’s bomber plant, and the demands for aluminum will multiply overnight. Actually the country may witness sight some assembly lines the slow-down for want aluminum situation that could probably have been avoided. And, what differ- ence 100 more planes may make some future Singapore. All year there has been one say nay the insistence the iron and steel industry for exces- sively pure aluminum for deoxidiz- ing purposes—and what large tonnage high grade aluminum has disappeared that direction! Nor has anyone critically examined stopped the absorption virgin metal for many aircraft parts and innumerable other armament uses tanks and naval vessels, when secondary metal could have been successfully used. the secondary field the government has created another those quaint anomalies that has many tragic overtones. Secondary melters can only sell their metal for which the whole, blindly refuse use anything but virgin metal. course the result that scrap aluminum practically drug the market secondary smelters can’t stock any more. And the same time the country treated public collection campaign that brought conglomeration ma- terial that way justified the segregation costs involved. What should long ago have been done— what should today done—is stop virgin aluminum from going into unnecessary outlets; dis- place virgin aluminum ondary metal great variety applications, and build large stocks virgin metal handle the very heavy new loads that are shortly inevitable. The nickel position fairly well hand, even though some wholly unnecessary loads were thrown that metal during the year. For instance, the insistence many metal firms for heat treating and annealing furnaces using elaborate conveyors, walking beams, alloy hearths innumerable other high- nickel castings, when car-bottom rotary hearth furnaces per- form adequately during the emer- gency far less initial cost. The imported metal, tin, far ex- cellent shape, for plenty trouble—Rising Sun trouble. Mag- nesium undergoing tremendous expansion, some quite curious character and best not discussed here. And, despite the complete in- adequacy magnesium output match armament needs, there is— until quite recently was—an as- tonishingly large amount orphan and high-iron magnesium kicking around the market. Here again more could done prepare for the tremendous added load magne- sium (and aluminum) going thermite bomb plants swing into production. The exploitation pattern the major non-ferrous metals, however, fade into cance when stacked against the 1940 1941 Percent Percent Tons Percent 3.6 1,629,849 1,722,302 2.4 51,400 0.2 531,528 0.9 15.1 7,964,923 16.4 9,501,300 15.9 15.6 14.3 9,870,258 16.4 3.0 (b) 4.7 2,814,454 4.7 2,296,355 4.7 3,572,534 5.9 8.3 4,019,219 8.3 5,813,518 1.3 999,858 2.1 2,809,238 6.7 8,098,874 16.6 28.7 9,365,834 19.1 10,119,324 16. 60,000,000 100% (a) Negligible, not available and All Other. (b) Included Pressing, Forming, Stamping. (c) Included partly under Furniture and Furnishings and partly under All Other. | | i 4 e i ci as as => io 00% long and continuing din accusa- tion, defense, confusion and debate raging around the steel industry. Steel metal tremendous and diversified tonnage, complex pro- duction and fabrication ramifica- tions, and general pretty tough nut crack into neat pieces for analyzing. The elusiveness basic data, the ever-expanding loads heaped onto the industry, the inter- play competitive relationships, the vagueness consumption in- formation, the overlapping mil- itary and civilian uses, the impact ing, the indefinite responsibilities and dreary confusions OPM, all contributed general blurring the outlines what has and what may happen the steel industry. Those sections the outline that can brought into focus, however, pretty well sum follows: (1) The bulk steel 1941 can directly traceable into so-called civilian consumption. See Tables III and IV. (2) Steel directly traceable armament needs 1941 was aston- ishingly small. Those tonnages not directly traceable are indefinite and probably never will determined. (3) When steel spokesmen say there enough capacity, they are referring enough for essential armament needs and certain pro- portion civilian needs. When government spokesmen say there isn’t enough capacity, they are re- ferring essential armament needs and certain proportion civilian needs. Why the two never seem agree can attributed indefi- niteness certain proportion civilian needs,” and vagueness what constitutes “indirect de- (4) 1941 practically war production suffered for lack steel. More railroad cars could have been had plates been available. And several instances shipyards were completed far ahead schedule and had wait plates. the other hand, certain shipyards used their priorities build exces- sive stocks. Specialized capacity, e., armor: plate, heavy forgings, etc., was general expanded apace with expanding demands. (5) Early 1941, everyone made the mistake becoming too beguiled with ingot capacity figure, not fully appreciating the difficulties inherent distortion the conventional product mix pattern. Hence, the difficulties re- sulting from the drastic shift from light heavy steels 1941. Steel MONTHLY PRODUCTION AND CAPACITY STEEL INGOTS AND CASTINGS MONTHLY PIG IRON PRODUCTION Millions net tons ingot capacity production ‘ Pig iron production | for projected new capacity throws additional burdens these heavy steels. (6) Exports 1941 fell consid- erably under first the esti- mates. (7) Production 1941 exceeded expectations: ingots 82,800,000 tons, per cent above the pre- vious year’s record output; finished steel—60,000,000 tons more; pig iron—55,748,000 tons. (8) Ingot capacity: Jan. 1941 tons; June 30, 1941— 86,148,700 tons; Dec. 31, 1941—88,- 000,000 tons; all through increas- ing size existing open hearths during rebuilds, and completion new units privately financed. (9) Pig iron capacity: Jan. tons; June 30, 1941 57,937,000 tons; Dec. 31, 1941—59,437,000 tons. All through larger hearths during rebuild, re- habilitation old units, private construction new blast furnaces. (10) Pig iron capacity end 1942 tons, quite likely; end 1943—67,000,000 tons, possibly. All increases gov- ernment financed, much needed protect planned ingot additions, and provision yet made for ore-carriers for 1943 additions. (11) Ingot capacity end Estimated capacity 96 per cent private ~ Estimated capacity 2 per cent government 4 \ / 98 per cent private & The Iron Age 1937 1938 1939 1940 1941 1942 THE IRON AGE, January 1942—53 Other. is- ell lly loy er- in- han nifi- 1929 1932 1942—-94,000,000 tons, maybe; end 1943—97,500,000 tons, un- likely. All the argument about ad- visability and feasibility expan- sion centers part the 1942 planned expansion, and all the 1943 planned expansion. None the less, very likely that much the 1942 expansion will reach comple- tion, involves primarily alloy steel for aircraft, tanks and tools; ordinary steel for ships, freight cars and boilers; armor plate for tanks, ships, gun mounts, helmets and planes; bessemer ease the pressure scrap; and Provo expansion concession stra- tegic necessity. (12) Steel makers have been and are complete sympathy with in- creases electric furnace capacity 1941 about 1,000,000 tons (up per cent), and recognize neces- sity for further additions, for instance, recently completed plans for new furnaces equipment for steel for aircraft tubing, which imperative. (13) For the most part, new ca- pacity additions have grated into existing plants. This also true the West Coast ex- pansion. Persistent political pres- sure was exerted locate new capacity the Coast, but operat- ing economics finally dictated lo- ‘ation Provo. (14) Probably many the fears about the post-war effect exces- sive capacity are somewhat exag- gerated. Some the new capacity definitely temporary uneco- nomic character and doomed die war’s end. And, anyhow, the general industrial health the na- tion after the war will domi- nated other factors, that the steel capacity situation will exert best only very small effect. (15) The general assumption that scrap shortages will seriously curtail steel operation 1942 probably over-emphasized. Quite likely this situation need not be- come too serious. However, before the whole thing over this coun- try going picked very clean scrap, and incidental pots and pans, and the steel maker going turn out good steel with progressively poorer grades ma- terial. (16) The war program will eat far into normal future scrap sup- plies that the bessemer converter will retain far more prominent position after the war than now occupies. (17) The war going wipe out the whole current complex structure highly diversified prod- ucts and analyses. The greatly sim- plified system that inevitable will extend into the period with considerable benefit both producer and consumer, probably accompanied lower prices. (18) Producers are learn how make armament and other high grade steels without high alloy content. The present complex ternary and quarternary nickel-chromium-vanadium, etc., al- loys will give way simpler con- stituent backed with more elab- orate heat treatments. These prac- tices will certainly survive after the war. (19) Many minor technical ad- are going accelerated. As, for instance, greater use ac- curate coining operation forging field. the very interest- ing building three new Ferro- stan lines, e., continuous electro- tinned sheet steel for dry packs and certain canning operations. The current operating unit Gary can handle 32-in. strip speeds well over 200 ft. per min. Output order 1000 base boxes hr. About tin used per base box, against lb. normal hot dip practice. This particularly important development view the possible tin shortage and the ex- panding demands that the tin plate industry will required meet. (20) There probably will little price change steel during the war. Perhaps few extra changes here and there, for instance the recent $10 extra placed hot rolled Cr-Mo bar used extensively for armor piercing shells. This steel has permitted 10-point car- bon spread, against 7-point spread for similar SAE 4150 steel. (21) one really has much idea regarding the shift demands 1942. Certainly the killing off passenger car produc- tion going release much flat rolled and alloy steel—but truck and military units are the same time going expand tremendously. The only thing sure that many changes are prospect. Whether the decrease civilian production will more than offset increasing TABLE Distribution* Finished Steel 1941, Hot Rolled Bars Sheetand and Sheet and Over All Track Rein- Wire Tin Bars Sheared) Spikes and Bands forcing Alloy Tubes Rods | | | (b) All other. 40,481 2,423,800 1,705,254 55,133 16,382 17,477 812,391 18,222 612,837 33,015 Total... 40,556 2,734,100 1,822,109 90,836 16,659 30,614 550,385 1,142,905 18,906 734,525 33,638 Container 487 7,434 22,871 19,092 908 2,270 Oil, gas, water and mining industry 118,816 7,492 50,902 64,565 7,515 31,606 4,122 Pressing, forming and stamping industry (a) Metal furniture ard office 2,933 3,840 3,238 66,821 221 1,924 17,774 12,762 (b) Hardware and household 787 9,790 62,048 1,199 4,751 11,820 7,853 20,083 45,962 225,722 7,089 13,170 41,360 46,267 Shipbuilding industry 711,550 1,385,771 5,578 1,005 1,309 200,901 42,743 12,818 4,128 Undistributed and miscellaneous 1,047,787 56,812 38,082 10,115 40,348 1,545,753 92,877 220,580 619,853 874,166 Data from various Government and OPM reports, American Iron and Institute, individual stee! companies, and estimates the author. groups. Automotive, aircraft and shipbuilding construction included respective industry 54—THE IRON AGE, January 1942 4 | military needs, only time itself will tell. course everyone’s pulse throbbing today with news cash the barrel-head. Then that curious lull, that always-apparent lull before the storm, early 1940 when orders dropped country bathed beautiful isola- and cooking elaborate plans for new and facilities. Steel tuted some new capacity construc- tion their own hook and be- battle and bloodshed, and any dis- tionism and solved with such facil- cause some prodding, and, being cussion 1941 steel production ity the economic, political and mil- somewhat frightened and baffled and distribution could perhaps itary problems the world with happenings Washington, set classified much bathos. But, shallow analyses and flip remarks. offices gum shoe artists there being year contradiction, The screws were really biting try find out what the hell was year record production and flab- early 1941, however, and cocky going on. bergasting scarcities, just what industry was hit orders galore backlogs climbed. did happen the record 60,000,- —delayed Christmas presents, Some companies, for instance, 000 tons finished steel produced seemed the average sales- Bethlehem, might find its backlog 194lisa subject well worthy man who continued battle for doubling the time takes detailed examination. And, such the more toothsome competitive sign shipbuilding contract. examination may well serve civilian accounts. became obvious that the industry basis which predicate But, all makers were confident could not meet obligations hand. least few possibilities and prob- ability meet demands with the last quarter the curve breaks abilities for only little tightening here somewhat tighter priority con- First, word about the load and there, some additional special- trols, the beginning allocations, thrown the industry. The graph ized capacity, few routine ma- limitations construction, and pages 50-51, far nipulations. The first Gano Dunn curtailment policies affecting con- writer knows has never been de- report, excellent analysis, justi- veloped before. fied this attitude. Political events choked off less essential demands movement total backlog the were the march, however, the interest defense. But, industry for the period 1937 Europe was disintegrating, the still the commitment sheet 1941 inclusive. Never before its dim outlines what being pretty heavily loaded. Then history have steel makers been Arsenal Democracy implied be- came the Hauck plan lift ingot subjected such insistent and little The capacity 10,000,000 tons, with sup- severe climb unfilled commit- shape the backlog curve didn’t porting pig iron and bessemer ca- ments. Look back the dear, break—rather started getting pacity. And with the Hauck plan reviled then but looks Gano Dunn report showing whether such expansion was desirable now retrospect. Then for more capacity else wiping necessary, desirable, practica- the Department Justice, prob- out certain civilian loads. The ble ing for soft spots the steel sys- second report was way cor- conclusion that capacity was ab- flected the unpredictable loads im- necessary load the body politic. Washington became city in- steel traceable directly Shortly thereafter came the juicy dustrial planners and tinkerers, military use 1941, and the spurt English orders, with all novices and outsiders setting tremendous quantities going business naturally the basis orders for the marketing steel civilian outlets, with equal Product and Consuming Industry (In Net Tons) Wire and Wire Plate Sheets and Strip Including Tool Wheels tributed | | | | | ! | Construction industry 93,743 260 91,189 15,148 788 9,342 1,327,332 (a) Defense plants, bases, cantonments 33,569 1,307 128,867 9,752 110 4,360 5,250 173,707 41,892 2,814,454 Cil, gas, water and mining industry Includes steel, otherwise impossible allocate, going converting and pro- cessing industries, i.e., wire drawers, bolt, nut, rivet makers, etc. THE IRON AGE, January 1942—55 ne hin Biss 3 A j ~ tremendous tonnage absorbed that vague intermediate ground that one can definitely label military civilian. Thus, cut civilian requirements skeleton levels, and the country will have steel its ears for military requirements. the other hand, proponements expansion insist that civilian cuts cannot safely made degree meet the flood military demands that are in- evitable the war progresses. Table shows the steel product and agency ruling the various orders. Table similar breakdown total unfilled commitments the turn the year, also product agency. There quibbling with the urgency tonnages going Lend-Lease, Army and Navy, OPA and other agencies. The divi- sion priorities, however, ac- counts for the bulk tonnage— this tonnage, its distribution and urgency has been the basis all difference opinion. The bulk backlog shown Table equivalent about one-half year’s production. Indica- tive the tremendous pressure certain products, however, the 4,586,149-ton backlog for plates, equivalent almost present ca- pacity for that product. For the most part, however, the forward position doesn’t look too discour- aging this writing, although many things can happen rapidly distort the picture that even little complacency unwise. complement the bulk data shown Tables and II, effort made herein examine 1941 consumption consuming in- dustry and product. secure these breakdowns was necessary tap many widely separated sources data and juggle with some fancy correlation the raw basic data. None the less, the feats prestidigitation are checkable various points, and believed that the overall picture fairly accurate. Table III shows tonnage and percentage breakdown 1941 con- sumption industry, compared with performances past years. Table more elaborate breakdown industry and product, for the year 1941 alone. course the most surprising figure both Tables III and the tonnage going major de- fense items, for instance ship- building, ordnance, projectiles, tanks, and the aircraft industry. 56—THE IRON AGE, January 1942 these items hardly account for per cent the steel deliv- ered. And, this basis would very easy, and also very foolish, come the conclusion that all the difficulty experienced during the year the industry could credited bloated civilian de- mands. But, nail going into cantonment war item, mile barbed wire farm can well war item, the retention civilian industry just bolster morale may war item, and what good airplane motor there railroad car haul it? Just where the line drawn between definite war demand and unnecessary civilian demand something many people profess being able answer but all truthfulness one can answer— can only experimented with cut and try basis. One definite civilian item, how- ever, the automobile. dustry has all year been subjected the bitterest criticism, and lately the most severe restric- tions, primarily because enormous consumer steel, and needed various armament in- dustries. hard deny that the automobile industry went little hog wild during 1941, chalk- ing almost record productions and sending the units along the public the wave high pres- sure selling, frequently based the fears the buyers concerning future inability obtain cars. the other hand, all too many people have recklessly advocated wiping out the industry during the year with particular concern for the hardships would naturally impose upon hun- dreds thousands workers. regretted that the whole problem was not handled more in- telligently, with the industry being cut down gradually and workers being absorbed nearby war in- dustries. The most conspicuous item Tables III and the 9,501,300 tons steel going the automo- bile industry during 1941, account- ing for 15.9 per cent the coun- try’s total steel, being considerably under the 1940 participation the industry the steel market. Defense (or war) work absorbed the automobile industry was about per cent January, 1940, gradually increasing month month per cent the last quarter 1941. 1940 the auto- mobile industry accounted for 7,- 689,000 net tons billets, bars, strip, plates, structural, etc., and alloy (alloy, 8.8% total) for passenger car units, trucks, buses, etc. During the same year only about 206,600 tons steel went war items such troop trans- ports, scout radio cars, jeeps, half tracks, etc. 1941 civilian cars and trucks accounted for about 7,962,000 tons steel, and defense units accounted for 1,413,000 tons. either 1940 1941, apparently about 69,923 and 126,300 tons re- spectively, went into munitions, tanks, marine and aviation engines, etc. examination the product distributions Table for the year 1941 brings forth some inter- esting points. Ingots, ac- counted for over half the ton- nage this group, reflecting course England’s tremendous need for steel this semi-finished form. The automobile industry chewed good quantity, and tonnage going ordnance was comparatively insignificant. Structural struction industry, much not traceable directly the war ef- fort, took over half the tonnage this group. Railroad yards accounted for over one- quarter. Ordnance, again, shows Plates—this the product which tightness has been con- spicuous late 1941, and the first put under strict allocation. The railroad, shipbuilding and machin- ery outlets took over half the available plates. Construction was the largest single outlet, with the bulk material this group going (mostly early 1941) municipal buildings, utilities, highways, and great mass mis- cellaneous uses trace. Both Lend-Lease and the automobile industry accounted for major tonnages. Hot rolled bars the automo- bile industry was the great outlet this group, dominating both the carbon and alloy groups. Surpris- ingly little steel was taken the ordnance and aircraft groups. Railroad and shipyards, together, accounted for the order per cent the total (excluding reinforcing bars). Pipe and tubes—here, usual, the oil, gas, water and mining group dominate the picture. Again, surprising how small amount has gone ordnance—the lar lar el; mi | must part show the miscel- laneous group. Wire and wire products—agri- culture usual dominates this group, with the automobile indus- try and miscellaneous stamping and forming industries account- ing for large quantities. War in- dustries account for little tonnage. Tin naturally, nothing else much importance this group but the container industry. anything, 1942 will show more than proportional rise tin plate, becomes necessary ship more food long distances the armies the anti-Axis world. Lend-lease alone expected take 930,000 net tons tin plate 1942, which over per cent the industry’s capacity. view the demands lead and the always critical position tin, has been astonishing the amount tin plate still going into beer cans, certain foods (baby’s, for instance), cigarette tins, etc., terne plate going into oil cans. All these uses are readily trans- ferrable the glass paper in- dustries. Sheets and Automotive, construction, miscellaneous form- ing and stamping, and containers blanket this field. Many observers contend that some this capacity can transferred plates, and already little this shift has taken place. Undoubtedly some the civilian outlets can cut considerably, but how much one can prophesy. any case the continuous mills supplying these steels will have work more plate and tin plate breakdown 1942 which may tend offset some gains this section. Tool steel bars—about half goes machinery and machine tools, about 5000 tons went aircraft, equal amount ordnance, approximately twice much automobiles. most these product classi- the automobile industry assumes very prominent posi- tion. Therefore, assumed that with civilian auto assemblies scheduled for almost complete cancellation February, great quantity steel can made avail- able for other more pressing uses. None the less this only part the picture. Most likely the same time there will concur- rent rise truck assemblies for replacement and use, along with great rises steels going into all the multitude mechanized army field cam- paigns far corners the world. There suspicion many quar- ters that the net amount steel made available for other uses will falk short rosy expectations. OST informed steel analysts and even certain government agencies make bones about their belief that any attempt lift ingot capacity additional 10,000,000 tons over the next months will not only dangerous but futile gesture. This because there will insufficient pig iron and scrap re- sources support such additions. fact, has literally become prac- tically proven fact that scrap collections next year may drop much 5,000,000 tons, and there any amount money available the industry bet that total ingot production 1942 will not hit 85,000,000 tons. startling hear such doubts the raw material situation, country lavishly blessed with the materials steel making. Com- pared with any other country, the physical position the United States perfecticn itself. Thus, the conclusion inevitable that some difficulties, when and they arise, will the result blundering half and ineptitude plan- ning. historian will ever able set down the day-to-day frustra- tions, politics and delays that have long characterized the pig iron program and some extent the scrap setup. And, course, steei makers themselves have been too materials and are finding difficult develop the ingenuity frequently shown certain other countries. the writer’s mind, safe bet that before this war over, steel makers will making steel, and good steel that, out mate- never before shoved into American blast furnace open hearth. steel making, like any- thing else, what can done de- pends great deal how badly needs done how badly individuals can frightened into doing something. For the sake simplicity, the raw material situation (for ingot production) breaks down into three parts: (1) Iron ore (2) (3) Pig Iron The iron ore position not par- ticularly severe, least far. Shippers really tightened sched- ules during the past season, wiped out many little inefficiency upper Lake loading docks, and got more ore boats than they thought was possible. All this, combined with exceptionally favorable weather throughout the season and late freeze-up (and the help few Ca- nadian boats), resulted record Lake movement during the 1941 sea- 80,116,360 gross tons, against the previous 1929 record 65,204,600 tons. Present stock lower Lake ports 45,000,000 tons, against the previous record stock 44,004,000 tons 1922. But, this situation not quite sweet appears. Ore consump- tion this winter will exception- ally heavy, and late break-up ice next spring could well cause much loss sleep. would pos- sible bring down more ore rail, however, someone would write off the expense involved. And, another factor cause concern interference with Bethlehem ore movements from Chile. All all, the ore situation not too serious, but some slips could well demand some drastic corrective actions. The country may yet see huge piles tinned and galvanized scrap, and enameled pots and pans, beside blast furnaces. Such sights were common pre-war Germany, and who can deny that Adolf got some pretty good war machines thereby. regards scrap, the writer with clammy palms considerable trepidation takes the position that ‘the situation might painted far blacker than really is. Here, definitely, problem requir- ing little realistic action out OPM. most pressing importance excess scrap tide the steel indus- try through the weather—a month which usually shows fall-off scrap collection and preparation. This added imme- diate flow could come through se- lective price action pull least some remote material. For the long pull, the situation calls for less gloom and more ac- tion. course, mills are going using scrap hitherto sneered at, before this war over. Already, mills have somewhat this condition, for when there not enough cream around, skimmed milk tastes pretty good. Real industrial No. (CONCLUDED PAGE 159) THE IRON AGE, January ip- rst in- es, for no- let er, ing ing the not fully engaged the year closed, due lack raw ma- terial, but construction govern- ment inspired and government fi- nanced steel ingot expansion was being pushed—a situation which some think paradoxical. Steel output has been below rated capacity for weeks, owing scarc- ity scrap and pig iron. Late December the scrap shortage was becoming more serious and plans were shaping whereby defense needs would taken care of, case scrap shortages, the ex- making facilities were pense ingot output not engaged rated armament business. More than 6,600,000 tons addi- tional annual pig iron capacity have already been approved under gov- ernment sponsorship. Most all this contemplated estimated ton- nage for the purpose protect- ing existing steel capacity (rather than supplying pig iron for addi- tional steel ingot capacity already approved) making antici- pated deficiency scrap collections over the next few years. Some relief was obtained towards the last the year when Bethle- hem Steel Co. and National Steel Corp. each brought two blast furnaces, thus enabling both com- panies add substantially their supplies Early this year will have en- larged one its Carrie furnaces and Tennessee Coal, Iron Rail- road Co. will have operation new furnace, while American Roll- ing Mill expected making pig iron new furnace Ash- 58—THE IRON AGE, January 1942 CAMPBELL Pittsburgh Editor, The lron Age ° ° ° land June July, 1942. Several rebuilding jobs and some new pri- vately financed additional furnaces are expected completed the end 1942 early 1943. Dec. 20, 1941, the Defense Plant Corp. had the construction approximately 6,- 620,000 net tons pig iron capac- ity built government ex- pense and involve about new blast furnaces. the latter part December some these fur- naces were preliminary stages construction, while most were blueprint stage only. Latest word indicates that the OPM has recommended, and De- fense Plant Corp. expected ap- prove, additional blast furnaces which, assumed, will take care increased government financed steel capacity expected com- pleted fall 1943 1944 and which will make total about furnaces approved rec- ommended since expansion plans were set up. this connection also expected that OPM will rec- ommend, and DPC will approve, additional steel ingot capacity over and above what has already been approved, but only deemed necessary since action will con- centrated projects already ap- proved. More important than the construction blast furnaces, how- ever, the absolute necessity for providing boat space carry iron ore down that these contem- plated new furnaces may operate. the present time, Steel Corp. has under construction five new ore boats but progress the ore boats which were projected and approved the government take care the increased pig iron capacity has been slow. far only have been ordered the Mari- time Commission. believed good authority that construction none these has been started, or, has, nothing tangible has yet been accomplished. view the heavy demand for Naval and Maritime plates and view the certain increase such requirements, there appears, ac- cording reliable information, chance that enough these ore boats will not completed suf- ficient time furnish ore the new blast furnaces unless definite and unalterable plan action immediately instituted. OPM has given material high military pref- erence rati