The Iron Age 1942-01-29: Vol 149 Iss 4

ary JANUARY 29, 1942 Rolling Mill operators depend upon LEWIS products for accuracy gaugeinrolling, simplicity oper- ation, rugged con- struction and improvements which always accord with the latest rolling practice. cold Lewis Three High t Merchant Mill Lewis Blooming Mill Mill LEWIS FOUNDRY BLAW-KNOX JAN 1942 lose let 0. TWO SECTIONS—SECTION ONE on- 4 o- “TEST FIELD METALLURGY (Right) Just let you know that make good heat-resistant bolts and nuts. The necessity revising alloy steel specifications has made Hoskins Electric Furnaces particularly useful metallurgical laboratories. Here are few several Hoskins small box furnaces used steel producer, establish heat- treating practice new alloys. The furnaces are built stand the hard-going, 2000° F., that this day demands. The Chromel elements are extremely durable and easy get at. Hoskins Furnaces are compactly built conserve space. They are made several sizes, and are described Catalog Hoskins Manufacturing Company, Detroit, Michigan. LEAD WIRE PYROMETERS WELDING WIRE HEAT RESISTANT CASTINGS ENAMELING FIXTURES SPARK PLUG ELECTRODE WIRE ALLOYS NICKEL PROTECTION TUBES THE IRON AGE, every Thursday the CHILTON CO. (INC.). Entered 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. ~ d JANUARY 29, 1942 VOL. 149, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor, News Markets Editor LIPPERT ROWAN Machine Tool Editor, F. J. Oliver Associate Editors JAMES Art Editor, WINTERS Editorial Assistants M. M. SCHIEN G. B. WILLIAMS 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 Nework, Seattle ° ° ° DIX, Manager Reader Service ° ° ° Advertising Staff Emerson Findl Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Robinson Don Harner, 1595 Pacific Avenue, Long Beach, Cal. Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout. ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub lished every Thursday. Subscription Price United States and Possessions, Mexico, Cuba, and South America, $6.00; Canada, $8.50: Foreign, $12.00 year. Single copy, cents. ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS. Vice-President EVERIT TERHUNE, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE This Week in. Editorial Tough Guys Without Strings Technical Articles Spot Welding Aluminum Lockheed Silicon Monoxide ...... Arc Welded Light Boats Reclaiming Metal Scrap Buick Makes Its Own Carbide Tools New Die Casting Contour Sawing Naval Gun Mounts New Presses Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Personals and Machine Tool Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Comparison Prices Finished Steel Prices Warehouse Prices Products Advertised Index Advertisers Copyright, 1942, by Chilton Company (!nc.) 118 149 . 104 110 Mr Charles Brinley, President of the Baldwin Locomotive Works speaking at ceremonies when Baldwin's first M-3 tank was turned over lo the Army. Baldwin needed steel immediately for model tank constructed quickly guide future production. Speed was the important factor, Baldwin turned Ryer- son stocks for immediate shipment the necessary steel. Ryerson alloy and carbon steels were shipped from stock the same day permitting work begin once. Through this quick cooperation help many other suppliers, Baldwin was able beat the official schedule. This illus- tration typical the service Ryerson rendering daily manufacturers working the National Defense Program. Thousands emergency calls have cut down our large stocks steel, however, are serving thousands customers accordance with the OPM plan and believe will able continue this service even restricted basis, for the duration our national emergency. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Detroit, Cincinnati, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. CERTIFIED ° JANUARY 29, 1942 ESTABLISHED 1855 ° Tough Guys Without Strings HAT America needs most today positions public importance, are guys” who know their business and who are given full power run it. You cannot manage nation’s war economy the basis debat- ing society, and committee management falls into this category. Nor can you the job appointing puppet head front man who has strings him that are pulled various groups persons behind the scenes. have apparently come that conclusion connection with pro- duction and purchases evidenced the appointment Donald Nelson our supreme authority these matters, accountable only the President, and the people the United States. was long step the right direction, even delayed one, replace the previous multi, mixed and indefinite lines authority that tangled and tardied these functions single, simple and straight trans- mission line between Washington and industry. Now that this has been done for purchase and production, the next thing for prices. matter fact, this should have been done first because how you can control purchase and production without con- trolling prices beyond comprehension. The price administrator should have full and definite authority his field does Mr. Nelson purchase and production. There should strings him except the one leading the White House and even that one should not pulled very often. hope that Leon Henderson will get this job and that Congress will see that the job has strings it. believe that Henderson the best qualified man the country our price boss. This statement may have more weight when coming from one who has not hesitated the past express criticism regarding some his actions and statements. However, during the past hectic months which has done such remarkable job “price minister without what has been able accomplish without legal power has convinced that has well earned the job and has learned how handle it. Henderson undoubtedly our best posted man price history and price theory. And his two recent years post graduate work with all sorts industry and all sorts people have added the vitally essential element practicality. knows that price control must shaped help and not hinder our goal “all-out” production. Henderson also “tough guy” with thick skin. But without these qualifications, would not have lasted minutes the free-for-all arena which has been battling. Industry has nothing fear from tough guy who knows his business. could have much fear from compromiser who 4 | } J /} | ¥ | 7 4 & q q ALL TANKS Will Cross Battlefields Combat tanks are, course, vital necessity for modern war- fare. But they are not the only tanks. There are others— tanks which will never cross battlefield, nor featured the headlines, picture magazines. These tanks are also vital America’s war program. Filled with gasoline oil our off-shore bases, carrying the water supply high above ground army camps, bearing im- portant chemical solutions scores new defense plants— thousands these tanks are playing their nonspectacular but essential part our country’s great emergency. For their construction, Inland regularly producing large tonnages plates and other steel products. Just for bomber plants—and ships—and shells—and countless other war requirements, Inland bending every effort deliver steel for these tanks when and where needed. Inland has but one job steel, steel and more steel help win the war. % LE — Sales Offices: Milwaukee, Detroit, St. Paul, St. Louis, Two pressure tanks built Steel service powder plant. Acid for the production explosives stored these tanks Army Ordnance Works. Inland Steel was used for their construction. \ ee ‘ Dearborn Street, Chicago City, Cincinnati, and Steel stored Inland URING the past three years, the rapidly increasing de- mands for greater produc- tion the aircraft industry have given great impetus the develop- ment equipment for spot welding aluminum alloys. Spot welding ma- chines have been improved and developed rapidly that the ma- chines available today are far supe- rior those which could chased year ago, while machines purci.ased three years ago are com- paratively unsatisfactory for spot welding aluminum alloys over 0.040 in. thickness. Prior 1940, with few excep- tions, the use spot welding aluminum alloys was limited non- structural parts such map cases, ducts, switch boxes, cover plates and other Secondary structures such en- gine cowling, nacelle cowling, doors and window frames were also spot welded. Today, there can added this list floor supports, wing ribs, removable panels stabilizer leading edges, most which are Primary stressed structures. July, 1939, new type spot welder was installed Los An- geles for demonstration the vari- aircraft manufacturers. This Spot Welding Aluminum Lockheed ° ° ° HARRY CHILES Spot Welding Engineer, Lockheed Aircraft Corp. ° ° ° Spot welding being applied more and more stressed members airframes. Concurrent improve- ments equipment and techniques have resulted con- sistent gains output welded assemblies. What has been accomplished along these lines Lockheed, partic- ularly with Sciaky stored energy welders, detailed the author. machine which was that time manufactured Paris, France, dif- fered many respects from the conventional single-phase welders which that time were the only type equipment manufactured the United States for spot welding aluminum alloys. The most impor- tant features this particular spot welder are follows: (1) The “stored energy” prin- ciple operation. (2) The use direct current for welding. (3) The variable pressure cycle. This stored energy type spot welder has probably done more permit the widespread use spot welding the aircraft industry than any other one factor. These welders operate from three-phase, a.c. supply, through three-phase type This energy stored magnetic energy the welding transformer- reactor. When the energy has reached preset value contactor opens the primary d.c. circuit, in- ducing very high transient cur- rent discharge through the secon- dary welding circuit. The 40-kw. spot welder, which welds aluminum alloys and including two sheets 0.081 in. thickness, draws maximum cur- rent amp. from 440-volt three-phase power supply. Single- phase a.c. spot welders the Lock- THE IRON AGE, January 29, 1942—29 | | a {Sa ° 1 a A 7 OSCILLOGRAM SCIAKY SPOT WELDER CYCLE OPERATION seconds Force 625" Seconds CURRENT SECONDS IG. showing current and pressure cycle Sciaky stored energy type spot welder. The material welded 0.064 in. 24ST alclad. heed shop having about the same secondary area and capable weld- ing the same material draw maxi- mum about 2000 amp. from 440-volt single-phase supply. These single-phase welders have nom- inal rating 250 kva.; actually the maximum demand 1000 kva. the 40-kw. (stored energy) welders which Lockheed has op- eration now were replaced single- phase welders, the maximum de- mand the power supply would 23,350 kva., compared with the present maximum demand 7990 kva. The present welding power supply would not handle this increase load and the necessary changes would very expensive. The power systems supplying many the major aircraft factories and practically all the sub-contractors could not possibly handle single- phase load this size. The introduction the reactor stored energy machines this country also greatly stimulated the development stored energy weld- ers that operate the condenser- discharge principle. 4 ¥ 30—THE IRON AGE, January 29, 1942 The pressure mechanism this welder designed that either constant variable pressure cycle may used. The pressure system contains two cylinders and pistons; the lower smaller piston con- nected directly the upper elec- trode holder and the second larger piston “floating,” that is, not fastened rigidly the electrode holder. Its force transmitted the electrode holder the piston rod pressing the upper side the lower piston. means two solenoid operated air valves and the necessary electrical control and sequencing equipment, the follow- ing variable pressure cycle ob- tained. (See Fig. 1): lower side both pis- tons opened exhaust and air applied the upper side both pistons giving large force the electrodes. The initial large force, which about three times the weld- ing force, compresses the material together the point welded, giving better contact between the electrodes and the sheets and also giving more even contact the faying surfaces the sheets. B—Air admitted the lower side the upper piston counter- acting its downward force leaving only the force the smaller lower piston the electrodes. the proper time, the main contactor closes and the charging current starts flowing. C—When the charging current has reached the proper magnitude, the main contactor opens and the secondary welding discharge takes place. After the welding current reaches the maximum, but before the current stops flowing entirely, the lower side the upper piston opened exhaust that the larger force again applied the electrodes. The high force the weld gives forging action which prevents the formation cracks the weld cools. upper side both pistons then opened exhaust and air admitted the lower side the smaller piston raise the upper head, completing the welding cycle. The first 40-kw. machines used the Lockheed plant were manu- factured France and did not prove entirely satisfactory production for the following rea- sons: (a) Excessive maintenance was required keep the machines op- erating satisfactorily. (b) were inadequate. The machines were too slow. Since then, manufacture these machines has been transferred this country, and many improve- ments design, better workman- ship and the use better materials have greatly improved their per- formance. These 2—Photo- micrograph (25 spot weld made two 0.064 in. 24ST alclad sheets under the condi- tions shown Fig. 4 | 7 | q 3 4 a / | ! | the lower eaving lower the itactor urrent urrent nitude, the takes urrent before piston the the the which cks air the upper cycle. used manu- not ory rea- was ntrols slow. these red prove- kman- spot welders have contributed greatly the rapid increase spot weld pro- duction Lockheed. Growth Department 1939 the entire Lockheed spot welding department, including six single-phase a.c. welders, the assem- bly section and the material clean- ing section, occupied rectangular area approximately 100 ft., 5000 sq. ft. floor space. Jan. 1941, there were four single- phase a.c. welders and two PMCO- stored energy welders the Lockheed production spot welding department. The assembly, clean- ing and welding sections occupied total floor area approximately 6000 sq. ft. Nov. 1941, there were five single-phase a.c. spot welders, two 450-kva. single- phase a.c. roll spot welders, 40-kw. stored energy spot welders and three 25-kw. portable welders the department. The total floor area now 36,504 sq. ft. The principle aluminum alloys welded here are 24ST alclad, 52S, 2S, 3S, and base 24ST extruded sections 24ST alclad. the total spot weld production about per cent 24ST alclad, per cent 52S aluminum, per cent per cent 3S, and per cent base 24ST. The above production averages are for all types and sizes aluminum alloy assemblies ranging from small inaccessible boxes containing welds large open panels con- taining several hundred welds. The largest assembly spot welded the P-38 intercooler skin assembly which approximately ft. long in. wide and contains about 6000 welds. Typical spot welded as- semblies are motor cowling, floor supports, window frames, nacelle cowling air ducts, wing ribs, doors, removable panels stabilizer leading edges. Big Rise Production During recent months spot weld creased very rapidly. The produc- tion rate for aluminum alloys only, for example, averaged 450 spots per welder per hr. for the week ended July (see Fig. 3), and 850 spots per welder per hr. for the week ended Oct. 31, increase per cent. For the same period, July Oct. 31, the average number as- semblies completed per week, all three shifts, has increased from 22,- 000 maximum 29,600 (see Fig. 4). The total number man- 950 in- 900 dividual pro- per hr. per weld- 750 per cent between 100 July and Oct. 650 31, 1941, due the text. Amore recent ment technique should raise the 450 departmental output 1000 spot welds per hr. per machine. ° ° ° hr. per week, including all assem- bly, cleaning, supervision and weld- ing this department has, during this same period, decreased from 61,000 44,000, releasing 150 ex- perienced aircraft men for work other departments. The assemblies completed per man-hr. has increased from 0.35 0.625. The greatly increased spot weld production rate and the general in- crease efficiency the spot weld- ing department can attributed the following factors: 1—Planned and controlled schedul- Week ending ing and routing work welding machines: (a) Performing all assembly work benches—not the welder. (b) Routing work the type welder best suited for the particu- lar job. (c) Routing all jobs requiring special set-ups one two three welders that operate constant- with special tooling, thereby eliminating set-up time. (d) Routing jobs certain material and thickness combination, which require special tooling, In- crease the overall efficiency spot welding has resulted greatly increased output per man- hr. and hence greater overall production, with much smaller working force. 0.80 0.70 035 Assemblies man-hour 0.20 Week ending THE IRON AGE, January 29, 5 q 7 7 7 s Cc = week —— ree” 5—Welding window frame for Hudson bomber with one the reactor type stored energy welders. one eight welders that may already adjusted for the specific material welded. (e) Planning scheduling work bench assembly section and re-assembly section that the right type job particular welder the right time. 2—Improvements the pre-spot weld cleaning method and shop equip- ment: (a) Installation four tanks ing oven the same size with over- 32—THE IRON AGE, 29, 1942 baskets into which parts are loaded for cleaning. (b) Installation electric timers tanks requiring accurate control time factor. The installation new cleaning equipment eliminated all hand op- erations except loading and unload- ing the baskets. Before installing the new equipment, men were required per shift the cleaning twice much work with only four men per shift. Ten parts ranging size from small angle cooler skin ft. have been cleaned one 8-hr. shift. The time etching the various kinds and thicknesses material the per cent hydrofluoric acid solution has been greatly reduced since all grease and foreign mate- rials are first removed 5-min. wash soap solution 170 deg. cleaning schedule for the vari- ous materials has also been set and maintained, thereby insuring consistent results. When parts are handled few time hand, extremely difficult control the process. The cleaning schedule which has been set with the new equip- Operation 1—Tank No. 1—Soak hot soap wash for min. remove all dirt, grease and other foreign materials. Operation 2—Tank No. 2—Rinse parts thoroughly cold running water with air agitation. Operation 3—Tank No. 3—Etch parts per cent acid solution per the following sched- ule: Material Time Thickness, Etching, In. 0.016 0.020 0.025 0.032 0.040 0.051 0.064 0.081 Operation 4—Tank No. 2—Rinse parts thoroughly cold running water with air agitation. Operation 5—Tank No. 1—Soak hot soap solution loosen gray- ish deposit surface alclad parts. Operation 6—Tank No. 2—Rinse cold running water. (Inspect: parts are still dirty, repeat Op- erations and 6.) Operation 7—Tank No. 4—Rinse parts thoroughly final hot rinse. Operation 8—Dry oughly hot air drying chamber. 3—Installation improved types stored energy welding machines. (a) All 40-kw. spot welders have been returned the manufacturer and rebuilt according the latest changes and improvements. 4—Proper maintenance. The new machines will operate satisfactorily speed 100 spots per min. 0.018 in. stainless steel and spots per min. 0.032 in. 24ST alclad. wr ter- een rial acid iced ate- nin. leg. ari- up ing are ind, trol has lip- oak These welders are operating hr. per day, but very little time lost due breakdowns, because the excellent work competent electricians, who have been as- signed spot weld maintenance full-time job. The man charge the spot weld maintenance group very capable electrician and has had number years’ experi- ence maintaining both a.c. and stored energy spot welders. maintenance schedule has been set whereby each machine checked once each day and certain adjust- ments made. Other major mainte- nance jobs such cleaning secondary contact surfaces are per- formed once each month. 5—Improved shop layout and handling material: (a) Adequate working space has been provided around each welder permit rolling parts trucks the welder. (b) small portable work table provided for each welder. (c) Special tables have been pro- vided support large assemblies while they are welded. (d) Special portable racks are provided for parts that cannot moved about parts trucks. Stand- ard parts racks are located vari- ous points where storage parts necessary. 6—Assemblies which were not designed properly for spot welding and consequently could not weld- economically have been changed riveting. 7—Changes the design spot welding electrodes, holders, etc. (a) Electrodes have been rede- signed prevent overheating. (b) Clamping blocks welding arms have been redesigned elim- inate slipping holders under high pressure. Clamping blocks have also been cut away slightly along half round cut-out block pre- vent holder from sticking the block. (c) Special welding arms and offset electrode holders that are properly cooled have been designed for inaccessible work. (d) Refrigerating equipment now being installed for supercooling the electrodes point below freezing. Installation this equip- ment and further increases over- all efficiency will raise the average production rate per machine ap- proximately 1000 spots per machine per hr. (e) complete set wrenches needed the operator are kept each welder. (f) complete set special 6—Roll spot welding (not seam welding) fuselage bulkhead for the Hudson bomber. This 450-kva. a.c. machine averages over 4100 spot welds per hr. not stored energy type. lathe fixtures and special tools has been provided for servicing elec- trodes and welding wheels. Ring gages and plug gages have been pro- vided for checking electrode tapers and tapered sockets holders. The progress which made due the various factors mentioned above would have been impossible without the full coop- eration the shop personnel and supervisors. Every man the shop has cooperated the fullest extent with the plant engineering depart- ment trying out new ideas re- garding the scheduling and routing work. Many the improvements made both equipment and meth- ods were suggested the men doing the work. The men the shop have been very cooperative and have demon- strated their initiative many ideas and suggestions. These men also have demonstrated that they know that “put out” plain hard work necessary get This well demonstrated the following facts: (1) Record spot weld production 0.018—0.018 in. stainléss steel, one operator, hr.—25,167 welds. Ma- chine PMCO-2S. (2) Record spot weld production 0.032 in. 24ST alclad hr., 20,- 134 welds. Machine (3) open aluminum alloy assem- blies, especially designed for spot welding, operators consistently pro- duce from 8000 12,000 welds, de- pending upon the particular job and the thickness the material welded. (4) Average spot weld production per hr. (22% working hr.) welds. These data given above not include the spot weld production the two 450-kva. single-phase a.c. roll spot welders. These two ma- chines have operated 22' hr. per day roll spot welders (not seam welding) for approximately six months, averaging 4137 welds per hr. average 186,165 welds per hr., for the two machines. The production these machines welding aluminum alloys equal that five spot welders, conse- quently Lockheed feels that from the economical standpoint roll spot welding has great possibilities. the time this article appears print, there will operation two new PMM-2B stored energy roll- welders which will greatly increase production capacity. THE IRON AGE, January 29, 1942—33 | | | q 7 | | q 2 nse ; | ing ay- lad nse ct: g nse or- q rer est q ily ily q q q q Monoxide Considerable evidence for the existence SiO steel making temperatures was presented last week. Herein, the authors conclude with data the importance SiO steel making, and examine the metal reactions. date there published information chemistry silicon monoxide dissolved form steel except the paper which this sequel.” The results investiga- tions Battelle Memorial Institute silicon-oxygen equilibria, which are reported that preliminary paper, offer some information indirect nature, however, from which several interesting approxi- mations may developed. From the data obtained that investiga- tion, the thermodynamic properties several reactions the postu- lated silicon monoxide liquid steel may derived. For clarification, the significant reactions can grouped as: (1) Those which SiO, reduced SiO the other components the system [Fe] [Si] and, (2) Those which reduces the other dissolved oxides form *Note that the only equations not em- ploying dissolved constituents are Equa- tions and Exceptions are these made for and because the solu- bility relationships for are not known and because the expression stands both valid and useful. 34—THE IRON AGE, 29, 1942 The reduction SiO, belongs definition both but included only the first. For these reactions the equili- brium constants are: **Since the experiments were all con- ducted the presence excess SiO:, and the solutions were dilute, the activities both and may regarded without introducing measurable error. ***These parenthetical expressions re- late the equilibrium constants used reference 36. Using the values derived ex- periment the present research,” possible calculate these con- stants for 1550, 1600 and 1650 deg. C., and then obtain their equations functions temperature. This information listed Table Fig. the first group re- actions, which reduced [SiO] the various components the system, depicted plot log versus 1/T. The slopes the curves for these reactions sig- nify that with increasing tempera- ture transforms more read- ° Research Engineer and Supervising Metal- lurgist, Battelle Memorial Institute, Columbus ily This consistent with the recognition silicon monoxide high temperature form. Fig. the second group reactions, which [Si] dized [SiO] various other oxide forms the system simi- larly depicted. The constant for equation III repeated this figure. The slopes these curves signify that will reduce SiO, and form SiO with increasing creases; but that the ability deoxidize FeO, with the assumed formation SiO this particular case, lessens the temperature in- creases, which well known. other words, higher tempera- tures the oxides silicon become progressively less stable contact with iron. From the relationship: the standard free energy changes the five reactions can derived: Similarly, the values for the standard entropy change and the heat reaction, which consid- ered constant over the temperature range under consideration, can determined. They are listed, along with standard free energy changes calculated for 1600 deg. C., Table II. There very little information with which these values can 7 fetal- ute, licon iture for this and ising compared. calculated several heats reactions based very rough estimates: 165,000 calories (2) (C) SiO (vapor)+CO 160,000 calories 355,000 calories The temperature range lay between making those the electric arc; conse- quently, little can said for the significance these figures. They are the only calculations record, however, and only equation which analogous equation III the present work, has any semblance the steel making reactions under consideration. Then the compo- nents are all whereas the present study the components are dissolved the common solvent, liquid iron, with the exceptions cited for and Determination the actual con- centration SiO liquid steel must await further research. Nevertheless, solution simultane- ous leads values that fit the experimental data closely that they merit some consideration until method for direct measure- ment can found. For the consideration SiO liquid steel, equation represents the most noteworthy reaction, be- cause signifies that [SiO] in- creases [FeO] decreases. Con- sequently, total silicon analysis steel will include proportion that will increase the total silicon content increases. This shown Fig. using the values derived from the present research, where [SiO] expressed terms glance the two equations: shows that [Si] increases the square [FeO], whereas increases only the linear recip- rocal [FeO]. Consequently, the increase [SiO] with shown Fig. considerably less rapid than the corresponding [Si]. illustrate this relationship, the ratio Fig. Equation again noteworthy because shows that the total oxy- gen content steel should reach Table Equation No. 1600°C., Calories AH, Calories +10,000 Calories Per Deg. +48 ,000 +13.5 +34.1 2.06 should then proceed increase the silicon content, and hence the SiO content, increases, although [FeO] continues decrease. This relationship dissolved monoxides has received consideration here- tofore studies the chemistry steel making. the relation- ship valid, and appears be, the total oxygen content steels containing such dissolved forms 2—Change must follow the type curve shown Fig. which was cal- culated from the derived values just mentioned. Such picturization oxygen steel unprecedented except for those desultory opinions that cast iron, high silicon steel, etc., often seem contain much more oxygen than can expected from extant data the equilibria. stants with tempera- ture for the group reactions which reduced [SiO] the com- ponents the liquid The slopes these curves for all three reactions show that tends transform the [SiO], with increas- ing temperature. Table Equilibrium Constant Variations with (°K.) Value the Constant 1600°C. 1650°C. 20,690 8.46 THE IRON AGE, January 29, = 4 ~2.30 | -2.40 I | | = 1,00 ° come -3.00 ved: the the nsid- nges 7 Slag Reactions The role SiO the chemistry refractories and slags, seems reasonable expect, may least important its role within the liquid metal. Indeed, silica and silicate refractories and slags are not too well understood, and the consideration any new viewpoint warranted. From the present work, pre- cise information can gained with respect slags and refractories except way inference. Never- theless, numerous so-called “anomo- lies” found described the litera- ture can explained simply the basis silicon monoxide that they invite further study. For example, over years ago, the 1850’s when metallurgical discussions were first corded, English metallurgist who collected slag samples found traordinary scientific The metallurgist was Percy; and his presidential address before the Iron and Steel Institute discussed this specimen, which described fibrous, siliceous aggregate, and pointed out that had published discussion the piece years before. Blair’ the same year described similar, white substance,” found botryoidal masses between the iron and brickwork blast furnace. Blair stated that the sub- stance, after lying for one and then for two years his desk, made hissing sound when water and that the evolved gas burned with blue flame. humorous now read that Blair tried boil the gas out the piece without success and, the piéce résistance, that found the substance would not give off its “occluded” gas when placed tur- pentine instead water. very likely that the substance consisted the room temperature decomposi- tion products silicon monoxide. SiO (or reacts with water liberate hydrogen, and hydrogen burns with blue flame. discussing Blair’s paper, Bell introduced another interesting as- pect this subject: The observa- tion that pig iron sometimes be- came covered with silica. year later, described observa- tion even more closely conforming the present conception SiO silicon iron steel. Turner found not only the exterior cast- ings coated with fibrous silica, but also the linings internal cavi- 36—THE IRON AGE, January 29, 1942 1550 1600 Tab ties. The most readily forthcoming explanation was that exudes from cast iron much does carbon kish, but Turner found diffi- cult account that basis for the fibrous structure the oxi- dized and for the fact that was also found cavities where the opportunity for oxidizing seemed remote. the present research, high- silicon specimens carbon-free iron quenched directly from the melt often showed siliceous coat- ing the lining interior cavities whose access either air water highly improbable. monoxide stands satisfactory explanation for such phenomenon. The high vapor pressure SiO makes its exudation likely, and such coatings may, therefore, pected. interesting observation what may have been silicon monox- ide occurs the published work Chipman and Li.” These in- vestigators were the chemistry liquid iron care- fully dried atmospheres and H.S. When silica crucible was used hold the iron, they observed that: “Due the sublimation silica, great deal black, amorphous substance collected the top the crucible and the furnace wall. This substance can de- colorized easily immersing HCl, but the main bulk the sub- stance remained undissolved. This substance, then, must mainly (possibly with some elemen- , deg.C. ° ° ° 3—Change equilibrium stants with ture for the group reactions which [Si] reduces the ides the system Fe-O-Si-H, form [SiO]. The slopes the curves indi- cate that and [SiO.] more readily with [Si] the ture rises, but that [FeO] less easily reduced [Si] higher Thus, Fe, which will reduce will likewise reduce [SiO] [Si]; and [Si] be- comes less effective deoxidizer when 1650 the temperature ° ° tary silicon) colored black iron and FeS which evaporated from the melt and finally condensed with this SiO, actually has scarcely mea- surable vapor pressure ‘steel making temperatures when under oxidizing conditions. Because vapor pressure only function tem- perature, all other measurements made under conditions where the vapor pressure appears high must discarded; consequently, could not have been silica that vaporized. Those authors specify that there was oxygen the atmosphere, which would necessary for form- ing SiO, from vaporized metallic silicon. Furthermore, analyses showed that the iron had gained large amount silicon, hence silica had been reduced, would ex- H.S. Thus possible that the semi-reduced form, SiO, was the agent responsible for their observa- tion. the present investigation ob- servations the same type were frequently made that conformed with the proposed role for silicon monoxide. sublimate similar the one described Chipman and Li, though not discolored sulfides, could produced vary- ing degrees will simply vary- ing the oxygen pressure the system. Under comparatively oxid- izing conditions, trace silica sublimate was ever found, which consistent with the known low vapor pressure but, the ‘ m ° q | | hange group which the system slopes react tempera- but that [Si] hich will likewise effective izer when iron from with mea- under vapor tem- rements ere the must could porized. there form- metallic ained silica ex- and hat the ob- silicon nilar and vary- vary- the oxid- silica vhich low the atmosphere was made more reduc- ing, sublimate soon appeared that became more voluminous the con- ditions became more reducing. The same observations have been made The silica crucibles devitrified more rapidly under reducing con- ditions, which observation that has also been made others.” That behavior again indicates that the vapor pressure SiO, ele- vated temperatures much lower than popularly assumed, and that its apparently great ten- dency vaporize under certain conditions really related monoxide reaction. The dependence the volatility the oxygen pres- sure the environment could thereby explained. Likewise, SiO terms weight percent 040 0.80 1.20 1.60 weight per cent ——> these observations indicate that silicon monoxide may play im- portant part the recrystallization vitreous silica elevated tem- peratures. Another possible occurrence silicon monoxide may the silicizing steel. found white powder the porcelain tube after cementing steel with silicon hydrogen atmosphere. Reduc- tion SiO, the refractories vaporous SiO could expected, but his assumption that certain con- densates were silicon hydride might questioned. The most stimulating observa- tions that can involve SiO, however, are found discussions the behavior silica high tempera- tures. Sosman, his book, “The Properties states that: The most striking fact about the crystallization vitreous gins only the surface and pro- inward.” This phenomenon was served the present work and was found vary degree with the hydrogen content the atmos- phere. later states: The rate crystallization vitreous silica cristobalite may also influenced the com- position the gas with which contact.” and points out that one investiga- tor reported having made new kind cristobalite fusing silica oxy-hydrogen flame and then heating 1600 deg. for hr. These observations are inconsistent with the kinetics crystalline transformation and certainly sug- gest that chemical factor, such SiO, operating. 4—This graph shows the calcu- lated concentration SiO liquid steel the total silicon content. Values lated for rium the system Again, Sosman states that: not all the observed vaporization silica true evaporation the compound ration there under certain con- ditions apparent evaporation which not due vaporization all but reduction and re-oxida- tion. reducing atmosphere, such exists carbon-tube elec- tric furnace, vapors silica are frequently seen, which result from (1) the reduc- tion SiO, Si, (2) volatiliza- tion the silicon, which much more volatile than silica, and (3) reoxidation the SiO, either through admixture with air through recombination with the original oxygen cooler part the furnace.” alternative this explana- tion, the commonly accepted one, the formation SiO, which then breaks down into could considered. Biltz and Ehrlich,” who demonstrated that can va- porize suboxide, showed that SiO: non-volatile and that itself should vaporize only per cent much was observed for the materials question. Sosman concludes reviewing the work Dufour, who showed that silica contact with and CO, respectively, sublimed only when contact with which con- forms with the present reasoning. Numerous observations the vola- tility SiO, when contact with carbon high temperatures are also discussed. The sublimates most cases were found differ from vitreous silica both density and hardness, which suggests that the substance could not have been The difference noted hardness alone invites assuming that another form exists. Thus, the other form might the SiO Si.SiO, decomposition product, for conditions were reducing. possible that one more Ratio SiO [SiO] [Si], plotted against show the calculated tion and [SiO]. 0.1 predominantly 0.20 0.60 1.00 1.20 140 1.60 180 2.00 THE IRON AGE, 29, 0.50 0.30 deg.C. ! of = the many silica discussed Sosman’s book also re- late silicon monoxide either di- rectly indirectly. For example, stated that fine white fibers were found pig iron Mallard, agreement with the observations Bell and Tucker just mentioned. SiO, reduced all three the principal ingredients pig iron; consequently, difficult see how SiO. could survive through the melting period. Those fibers may very likely have been from previously dissolved silicon (1) Silicon monoxide not only may exist steel-making tempera- tures, but may signal impor- tance the deoxidation process. (2) Silicon monoxide may con- ceivably formed liquid steel from reduction SiO, from oxidation Si. The five principal equations for such reactions the system Fe-O-Si-H have been de- fined and their thermodynamic properties calculated the basis results obtained from vestigation silicon: oxygen equilibria liquid iron. 0.22 Limit solubility for Feo— | | 5—Plot show- how may affect the total oxygen content weight per cent steel 1600 deg. weight per cent ——> monoxide, although the substance observed room temperature was SiO, described be- fore, the monoxide may form SiO, both decomposition and oxida- tion, Although Sosman makes men- tion SiO, the statements just listed, and many more that can found throughout the book, con- form closely the observations made and the conclusions drawn the course the present research that they deserve further investi- gation. There indication that the monoxide silicon may play important part the behavior silica, and probably likewise silicates, high temperatures. The possibility that monoxide silicates may exist steel making tempera- tures brings with world conjecture. Conclusions The foregoing discussion leads several important conclusions: 38—THE IRON AGE, January 29, 1942 (3) Increasing temperature and decreasing oxygen pressure favor the formation Conse- quently, diminishes, the total oxygen content may actually increase. The calculated quantitative relationship respect ordinary silicon content may predominantly whereas higher silicon contents, although [SiO] also maximum there, the predominating form haviorisms slags and refractories high temperatures may caused silicon monoxide. Acknowledgment Acknowledgment made Bat- telle Memorial Institute for the support this investigation part its program fer funda- mental research. Bibliography *Blair, T., “On Certain Accessory Products Blast Furnaces,” Journal the Iron and Steel Institute, Vol 29, 1886, pp. 81-87. *Percy, J., President’s ibid., Vol. 29, 1886, pp. 8-31. *Turner, T., “Production from Cast ibid., Vol. 31, 1887, pp. 203-211. C., “Reduction Oxygen Compounds Deut. Chem. Ges., Vol. 23, 1890, 2642-2668. Silicon,” L’Industria Chem., Vol. pp. 182-183; also, Genie Civil, Vol 52, 1905, pp. 274. Potter, N., French patent 360,- 875, 1905; British patent, 26,788, 1905; and German patent, 182,082, 1905. tric Furnace,” the Address, American Vol. 1905, pp. 243-249. N., British patent, 1279, 1906; French patent, 366,644, 1906; German patent, 189,833, 1905. Compounds,” Transaction Amer- ican Electrochemical Society, Vol. 12, 1907, pp. 229-239. Potter, B., ibid., Vol. 12, 1907, pp. 215-222. Potter, N., “Production New Electric Furnace Product,” ibid., Vol. 12, 1907, pp. 223- 228. Potter, N., “Silicon Monoxide,” ibid., Vol. 12, 1907, pp. 191-214; and abstract Engineering, Vol. 85, 1908, 722 (ae. Engineering, Vol. 85, 1908, 722. Bock, F., Innovations the Technical Utilization Silica,” Ztg., Vol. 35, 1911, pp. 231-232. Hermann, S., “Innovations the Realm Silicon Compounds,” Zeit., Vol. 17, 1911, pp. 190- 192, 220-223, 250-253, and 279-281. ing SiO,” United States patent, 384, July 21, 1914. Schmitz, F., “Influence Gases Iron Exposed Their Action,” Stahl und Vol. 39, 1919, pp. 373-381 and 406-413. Flusin, R., “Silicon Monoxide and Oxycarbides. ‘Monox and Industri Chemique, Vol. 1922, pp. “The Monoxide and Oxycarbides Silicon,” Chemical Transactions Journal, Vol. 71, 1922, pp. 445-446. Jevons, W., “On the tra Silicon Oxide and Chloride, and Chlorides Carbon, Boron, and Alu- minum,” Proceedings the Royal Society, Vol. 106A, 1924, pp. 174-194. Mellor, W., Comprehensive Treatise Inorganic and Theoretical Chemistry,” London, Longmans, Green Co., Vol. 1925, 1024 pages. 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Baumann, N., Jr., “X-ray Dif- fraction Examination Material Having the Composition SiO,” trochemical Society preprint 80-9, October, 1941, pages. H., “On the Silicon Oxide Bands,” Bulletin the Amer- ican Physical Society, April 17, 1941, 15. Zintl, W., Krings, Braun- ing, “Process Removing Silica From Minerals, Slags, and Similar Materials,” United States patent 2,- 242,497, May 20, 1941. “Silicon-Oxygen Equilibrium Liquid Iron,” published the Amer- ican Institute Mining and Metal- lurgical Engineers. New Pickling Bath Agitator Jets speed production and re- duce rejects pickling with- out the expense and space required for installing additional pickling tanks, Heil Co., Cleveland, has developed new series steam- air agitator jets. Increased operat- ing rates, accomplished uniform heat together with bath agitation, claimed for these jets, which pro- vide both temperature requirements and the agitation necessary over the area within their range. stated that mills have reported much per cent tonnage in- creases and speeds increased from 110 ft. per min. pickling operations their use. feature the new jets that the proper bath temperature has been reached, the steam shut off and air agitation commences. Also, air admitted with the steam has several advantages over the use straight steam, such the saving per cent more acid consumption, effective pickling lower acid concentrations, and Increase the tonnage pickled. The outstanding characteristic these new jets their orifice, Nocorodal (graphitic carbon) nozzle plate that fas- tened the tip the jet. This unattacked the acid solution, being able withstand boiling solutions with concentra- tions high per cent. Fur- thermore, they have unusual resis- tance mechanical wear steam. | | RRANGEMENT the steam-air agitator jets inside the pickling tanks. The E-3 type for continuous picklers, (B) the E-4 type for batch picklers, and the type for tube picklers. The jets, known the series, are made three different styles: the E-3 type for continuous pic- klers, the E-4 type for batch pic- kling, and the E-12 type for tube pickling, illustrated. The con- tinuous pickler jets are installed the bottom the tank along its sides, and extend the middle the tank from each end, assuring complete agitation throughout the tank. Nozzle openings are spaced about 15-in. intervals, and are directed horizontally along one side the tank and vertically along the other side. This arrangement causes the pickle liquor agi- tated and circulated from below and rolled over the top the continu- ous strip rotating manner. modification the continuous pickler jets has been devised for batch pickling. These jets are built tree-shaped for placing centrally along the bottom the tank. The nozzles force the pickle liquor through the sheets, which are usu- ally set edge during the proc- essing. The E-12 jets for tube pickling are located one end the tank, and permit either steam air blown into the bath, forcing the solution through the tubes. This action removes the ganister and permits effective pickling the in- ternal tube wall. THE IRON AGE, January 29, 1942—39 | | | | 7 Arc Welded Light Boats ANY advantages welded steel construction boats have been obvious, but con- struction light pleasure, coast guard, Naval patrol boats, arc welding* presents special problems that arise the relatively new art steel boat fabrication. Welded construction light boats Revere Copper Brass de- scribed THE IRON AGE, Aug. 1941. Engineers the Burger Boat Co., Manitowoc, Wis., find that one the most positive advantages the welded steel boat, aside from its admitted strength, fire-proof and leak-proof qualities, lies the fact that water-proof bulkhead construction feasible, permitting the construction safer boat. wooden boat the closure and seal- ing sections not considered good practice because the seams be- hind the bulkhead will leak slightly and rot likely set in. arc welded boats, shown under construction Figs. and water-tight bulkheads made steel plate are utilized, many four boat. These are reinforced horizontally and vert