The Iron Age 1942-04-30: Vol 149 Iss 18

APRIL 30, Va. 25.00 36.40 MOLYBDENUM HIGH SPEED STEEL carburize 1000 unit for this application will also harden tool steels Hy-Carbon, 51.30 Hy-Chrome, air hardening tool steels. 56.00 SECONDARY TREATMENT HIGH SPEED TOOLS. These tools, whether 51.00 purchased made you, this treatment will produce mini- mum 70% longer life when processed Holden Hy-speed Case. ALUMINUM NON-FERROUS ALLOYS. There Holden for 58.90 application. 9.00 SPECIAL BATHS FOR DESCALING bright tempering eliminate sand blasting pickling. One client saved 200 tons product 54.00 PROVEN RESULTS. Both equipment and materials are now use more than thousand incustrial plants. Temperature Range $76.00 2400° Heat Treating Furnaces—Gas, Oil, Electric. HEAT on ; = Holden Products made PEACOCK BROTHERS, Quebec GET MORE PRODUCTION FROM OLD and NEW TURRET LATHES “a are many ways can help you: Newer, better tools for turret and cross slide; improved spindle accuracy with new collets; turret lathe rebuilding instruction; develop new tooling setups; job studies and turret lathe department study our field service men and sales engineers; Operator’s Service Bureau offering learner courses; Operator’s Manual; cutter grind- ing sound-movie; special operator ‘ag OFF UNCLE SAMS SHOULDER Cleveland M APRIL 30, 1942 149, NO. VAN DEVENTER and Editor BAUR Vice-President and General Manager News Markets Editor, ROWAN Associate Editors JAMES Art Editor, WINTERS Editorial Assistants Washington Editor MOFFETT Resident District Editors CAMPBELL HERMAN KLEIN Pittsburgh Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis BACON Seattle DIX, Manager Reader Service Advertising Staff 621 Union Cleveland Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit 100 East 42nd St., New York Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. lished every Thursday. Subscription Price North America, South America and Possessions, $8: Foreign, $15 Single copy, cents. ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices estnut and Séth 100 East 42nd St. Philadelphia, Pa. New York, OFFICERS AND DIRECTORS MUSSELMAN, HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Editorial The Seventh Column Technical Articles Desulphurizing the Blast Furnace Faster Arc Welding with Less Electrode Material. Blast Furnace Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Personals and Obituaries Machine Tool Activity. Non-Ferrous Metals Scrap Iron and Steel Scrap Prices Comparison Finished Steel Prices Warehouse Prices Products Advertised Index Advertisers Copyright. 1942. by Chilten Company (ine.) This Week in... | i 120 | 134 4 | | —$—$—$—— 26—THE IRON AGE, April 30, 1942 and COOLING Transformers DESIGNED BUILT INSTALLED Mahon Engineers How Mahon engineers save manpower keep production rolling through faster and better practically demonstrated this compact Mahon in- stallation. Its purpose AUTOMATICALLY dry and cool huge ton transformers, after painting. half hour intervals, the power-operated doors, which enclose the Unit either end and separate the drying and cooling compartments, automatically are raised. Simultaneously transformer moves the platform conveyor and the doors close. Each thirty minutes, there- drying compartment after, the work moves one position—60 minutes the drying compartment, minutes the cooling section —and then out. Doors, conveyor, heating and cooling equipment, all are timed operate unison. Result: manpower released time and money saved drying and cooling accurately controlled. may that your product not massive, nor requires such intricate finishing equipment—but, whether large small whatever the equipment you need—washing, drying, painting baking—consult Mahon engineers. They will analyze your product and will advise you fairly and impartially what can done speed your production line. The Seventh Column HERE one thing that you can quite safely bet and that that the American people, whole, are going insist upon our win- ning this war. And the same token, the American people are not going stand for any “monkey business” that interferes with this great purpose, once they detect going on. This, think, evident from the tidal wave public demand that has descended upon Congress connection with union labor practices rackets which have hampered are hampering our all-out efforts this country. Thanks aroused public opinion, these vicious practices are slated for the “ash can” and any legislator who thinks differently acts contrary the public will this matter may well find himself heading for the same destination election day. Next due for public attention and action, think, the which has been sticking its head out the ground during the past few months and wriggling its forked tongue. legitimate descendant the same family invertibrates which, consciously unconsciously made the job easier for him during the preceding war. APRIL 30, 1942 The target for the venom these slimy invertibrates during 1917 and 1918 were the “swivel chair Washington and elsewhere this country. What was inferred from their out- givings was that any officer enlisted man who was compelled ESTABLISHED 1855 stay this country because did not have the privilege being sent overseas was poltroon and coward. wore spurs,” they said, “to keep his feet from sliding from his desk.” Today, the target for the descendants this same group inverti- brates, none whom, incidentally, are the armed forces either abroad home, are the business men and industrialists America. Espe- cially those who have answered their call and gone Wash- ington, elsewhere, serve for dollar year. They, and American business whole, are now being subjected the most contemptible and slanderous campaign vilification that this country has yet been unprivileged see hear. this sort stuff does not work directly for the benefit Hitler and Hirohito, miss guess. Even though may “red herring” that being drawn across the trail labor racket reforms, some- thing that doing untold harm the American and Allied cause. think that the average American reject this foul propaganda and sufficiently patriotic eject its perpe- trators. | | | y 4 | q | | | { & Privileges and Obligations Together You not have tell Jimmy’s dad that privileged have Jimmy— privileged watch Jimmy grow and develop free country. Nor you have tell him that has the obligations safeguard see that grows strong man—an intel- ligent man—a true American with pride his heritage freedom and with strong sense duty his country. Like Jimmy’s dad, Inland have always be- lieved that all privileges have correlative obliga- tions—that keep the privileges freedom must faithfully fulfill our obligations free government. SHEETS STRIP TIN PLATE PILING BARS Sales Offices: Milwaukee, Detroit, Loui That why, times peace, Inland steadily expanded its mills, developed new methods, delved deeply into research—all the end that America and her industries would have the right kind steel, the right quantities, help America grow. When war clouds gathered, considered Inland’s duty respond with steel needed for defense. Today, Inland expanding output, work- ing day and night without pause help America win carrying the fight the aggressors. the eventual peace Inland, all industry, and all patriotic Americans will still enjoy the privileges freedom because fulfilled obligations. FLOOR PLATE STRUCTURALS TRACK ACCESSORIES & — = { UCKLED and reared lush economy plenty, the Amer- ican steel industry climac- teric 1941 has already been im- pressed with the bitter fact that necessity, the proverbial mother invention, occasion rather grim dame, somewhat bewildered whirlwind courtship, shot- gun marriage, and Caesarean operation. The necessity for suc- cessive record quantities steel out third-rate scrap, the need for more and more quality steel notwithstanding dwindling supplies alloying elements, and demands steel shore soft spots other metals (cartridge cases, air- craft, etc.), all have been faced for the first time, faced that, with remarkable aplomb and commendable lack fanfaronada. Now there disruption that long-established sensitive relation- ship between tin miners distant Malaya, producers steel Pitts- burgh, and growers vegetables California. Consequently, the in- dustry’s new baby—electrolytic tin plate—can longer left slow- mature elegant conservatism, but sheer necessity must quickly and effectively assume dominant role that America may eat. Oh, and how popular baby today! Only few months ago electrolytic tinplate’s father spoke him al- most with apologetic reluctance, but today variety fathers, foster fathers, godfathers, and miscel- laneous consorts coo goo and march him proudly down the ave- nue. tary problems into sharp focus Japan’s Pearl Harbor coup main, cer- LIPPERT Managing Editor, The Age tainly far from the least was the certainty abrupt liquidation the very neat and tidy international cartellization world pig tin pro- duction, characteristic the in- dustry since 1934. Just about the time the scandal the Penang evacuation was shocking the Allied world, even became quite obvious professional optimists that the United States, country using over half the world’s tin, was destined have squeak with stocks hand and afloat, and moderate flow from Bolivia via Jesse Jones’ Texas The harsh cathartic necessity cut through the usual mental costiveness Washington, and plans were whipped with exemplary speed for strict allo- cation existing tin supplies. Bearing makers scurried re- explore low-tin and tin-less bearing alloys, and solder producers March (order M43A) were forced drop the tin content certain solders and shifted atten- tion the various low-tin-silver- bismuth-lead solders and the tin- free lead-silver alloys. The doom colldpsible tubes was and impregnated fabric, paper, and silver were scrutinized desper- ate haste. For the $500,000,000 tin plate section the steel industry, how- ever, the consequent upheaval really dramatic proportions, laced with many competitive overtones and technical ramifications. Both the tin plate industry and the Gov- ernment have initiated extensive pattern moves stretch the mea- ger tin supply. For over two months now governmental regula- tions have been force prohibiting the use tin for purposes not es- sential military civilian sub- sistence (WPB order M-43-a, kill- ing off toys, household novelties, sizes Nos. and 10, and re- stricting size packs for various foods secondary importance (WPB order M-81, Tables and scale based past methods and uses has been adopted. But unfor- tunately, these moves alone were only minutiae the over-all solu- tion the problem. Quite obviously became im- perative that the allocation tin take the following order prefer- ence: (1) Munitions. (2) Food containers for the armed forces. (3) Food containers for Allies (Lend-Lease). (4) Civilian subsistence. The Government estimates, based the various regulations issued date, indicate the quantity pig tin available for tin plate produc- tion 1943 will about 24,000 tons. However, there seems some confusion amongst different parties the estimated 24,000 tons metallic tin available. Some authorities have used the figure gross tons and some net tons. There has been much misunder- standing this subject that one quite able authenticate either the 24,000 the variety ton, but the chances, making allowance for confusion and uncertainty, seem favor the gross ton. The tin used THE IRON AGE, April 30, 1942—29 the production terne plate provided separate allocation (about 5,000,000 boxes for 1943). But the other very sharp horn the dilemma that further esti- mates show that tin mill product requirements for 1943 for all pur- poses will 76,000,000 base boxes the industry’s terminology, roughly 3,258,000 gross tons. Over the past decade average conversion has dropped from theoretical 100 about tin plate per base box. Now, since order M-81, size and gage plate for standardized cans has run the tin plate per base box. This latter figure used herein. For many years the standard practice has beem use 1.5 of, tin coat one box coke tin Subject minor exceptions the Government progressively forced this tin down (WPB order M-21-e) current weight 1.25 Ib. per box tin plate, with cer- tain exceptions, civilian and mili- tary (average about 1.27 which used herein). coating usually conceded the very minimum quantity which can satisfactorily applied the generally employed hot-dip process. Therefore, little calculation shows that this figure, 24,000 gross tons pig tin will hot-dip coat 42,000,- 000 boxes, against the requirement 76,000,000 boxes. This severe un- balance has made necessary for the Government wipe out some the casual uses more cushy era, prohibiting the use tin plate making containers for com- modities such dog food, tobacco, beer, dried beans, pork and beans, baking powder, cereals, flour, petro- leum products, spices, condiments, etc. The resultant savings tally about 6,000,000 boxes. The problem before the industry, therefore, boils down the follow- ing: Total quirement Less amount 76,000,000 boxes which can have no tin.. 6,000,000 tin may used. 70,000,000 boxes But regardless the severest rationing, allocating other mis- cellaneous arbitrary procedures at- tempted, the Army, Navy and civil- ian population can’t win the war bloated stomachs—they fed. And there sensible sub- stitute for the metal container taking care any appreciable part this problem. Certainly glass con- tainers are impractical, because weight, fragility, use rubber the closure, exposure contents light, cause packers are not equipped handle glass volume and would require two years square away for such task. And, unfortunate- ly, people can starve death days. Dehydrated foods, growing somewhat acceptance, are also severely limited because success for only certain types food, and because the need pure water the point consumption—for ex- ample, powdered tomato juice plus Philadelphia water would in- teresting experience indeed. And, longer can armies copy Genghis- Khan’s Mongols, who route-marched over degrees longitude, living off the land and opening the veins their spare mounts for fre- quent blood cocktails. For all these reasons thus be- came the responsibility tin plate producers and the can makers out practical answer the canning problem, not only prove their own viability but also pre- vent jeopardy the war effort. And, most creditably, solution has been devised, the recommended ap- proach being follows: Pig tin available Total need Quantity which must dipped: Armed forces and Allies Civilian 24,000 gross tons 70,000,000 boxes 20,000,000 boxes 19,000,000 boxes Total ....... boxes The 30,000,000 basis boxes which must hot dipped will account for 17,300 gross tons pig tin, leaving 6700 gross tons. The problem thus narrowed down providing the country with 40,000,000 boxes material for food containers and us- ing not more than 6700 gross tons pig tin the job. The solution for the industry produce: 30,000,000 boxes with 0.5 tin coating. 10,000,000 boxes with lacquered The electrolytic method plating the only process which will yield usable plate with 0.5-lb. coat. The United States Steel Corp. has very successful line operation the Gary plant, Crown Cork Seal Co., Inc., has already plated over 1,000,000 boxes Baltimore, and Crucible Steel Co. America has line Midland, Pa. Three new lines are now nearing comple- tion the Steel Corp. (THE IRON AGE, Jan. 1942, 54), Crown ready turn over and faster line, and there scat- tered amount new capacity the moment actually under way. regards capacity for the chemical treatment black plate, which the necessary preliminary for large scale lacquer coating, the Steel Corp. has the only unit actually pilot line Gary tin mill, Car- Steel Corp. There are, however, great many plans brewing the industry, and the tin plate producers and the can companies and the packing indus- try fully understand the situation and realize there alternative course open. Reducing everything figures, the material and process setup for 1943 follows: Gross Tons Tin Process Boxes Used Hot dipped ..... 30,000,000 17,300 Electrolytic coat 30,000,000 6,700 Chemically treated 10,000,000 Plain black plate 6,000,000 *See THE IRON AGE, Feb. 19, 1942, for analysis Boliv- ian tin possibilities for the The Texas refinery will soon initiate production the rate 18,000 tons per year, later may move 24,000-ton pace, and may even eventually shifted 52,000 tons year, the latter accelerated cycle turning out tin containing im- purities and usable only electrolytic installations. The following reviews the world-wide set-up: Purest ores are found Dutch Islands Banca (now Jap), the impurities being such nature that tin 99.9 per cent purity obtainable from ore smelted ordinary reverberatory furnace. Extensive Malay ores (now Jap), were generally treated two smelters, one Singapore and the other Penang. Cornish, England, output (not large) comes from mines 3000 ft. deep, the mines frequently extending far under the sea, with miners working warm water their waists. This makes cost winning the ore very 30—THE IRON AGE, April 30, 1942 high. Bolivian ores also are rather costly they occur 10,000 ft. above sea level area devoid fuel. This ore concentrate (60 per cent metallic tin) shipped Liverpool for refining, and considerably poorer concen- trate coming the new Texas refinery. Nigerian ores also are shipped Liverpool, England, refinery, but the concentrates assay about per cent tin and the impuri- ties are not difficult eradicate those the ores from Bolivia. All the Cornish ores are mixed with those from Nigeria and Bolivia and reduced the same smelter. East Indian isles Banca, Billiton and Sinkep (all now Jap) formerly fed Banca and the large Arnheim, Holland, smelter (now German), and the Belgians had smelter near Antwerp deal with the rich low-cost Belgian Congo ores. Important quantities tin were also produced China (now Jap), Siam (now Jap), and Australia (Tasmania). — rec set tic tic m Inasmuch problem encoun- tered the steel industry within recent years has been subject much distortion, surplusage, and misinformation, the data already set forth should clarify the outline the electrolytic tinplate situa- tion. And, the following observa- tions should help bringing various phases the problem into proper focus: (1) Some form tin plate the only material that fulfills funda- mental requirements for sanitary food can—(a) providing base for lithographing and protection can exterior against rusting storage, (b) internal protection against cor- rosion contents, alone with enamel, (c) contributing the maintenance clarity and natural flavor the food, and (d) particu- larly important, permit soldering body seam can machines speeds 300 more per min. Welding the side seam still not nearly fast enough commer- cially feasible. And while dry pack- age cans have crimp body seam, sanitary cans may undergo in- sq. in. during processing, and absolutely impractical conceive crimped side seam sufficiently tight and strong withstand such pressure without leaking. (2) Work progressing the bonderized material. Lead-tin sol- ders have been used oil cans for some time, but there are still many bugs high speed sanitary can fabrication. save even the small amount tin such solder, atten- tion also being given lead- silver solder alloys, although such application certainly cannot yet called commercially feasible. None the less, there inherent reason why cannot worked out attention such features mechanical cleaning, active flux- joined solderable coating such silver, etc. One particular diffi- culty solved the 2.5 per cent silver-lead solder the high melting point the entectic and absence spread between li- quidus and solidus temperature, Which introduces the problem Wiping excess solder from the can turn will require extensive changes for satisfactory Performance. (3) Electrolytic plate carrying 0.5 tin per box goes far meet the fundamental requirements soldering conventional the joint often showing resistance rupture 100 lb. per sq. in. This strength satis- factory for all canning needs. (4) Large quantities the elec- trolytic plate will used ends for can bodies made hot-dip plate (ends are curled and seamed on, not soldered). And, sizable tonnages chemically treated plate, subse- quently enameled, will used ends for can bodies made electro- plate. (5) Plain black plate (oiled, lac- quered, with size coating) will, available, into dry packs, such coffee, biscuits, tobacco, tooth powder, spice, lye, etc. Also, such borderline products oil, wax, shoe polish, certain bottle caps, screw caps, etc., etc. (6) Electrolytic bodies plus chem- ically treated ends, will make cans for non-corrosive vegetables such peas, corn, tomatoes, string beans and perhaps for fruits such peaches, apricots, pineapples, pears, etc. (7) Cans made hot-dip plate, and some electrolytic plate, will used for baby foods, milk, some the highly corrosive fruits such loganberries, black cherries, prunes, etc., and for much the food for the various AEF’s. And cans hot dip bodies plus electro- lytic ends will carry much the burden for export products such beer, lend-lease material gen- eral, and the lower acid foods for the military. (8) Additional exploratory and experimental work will required establish the adaptability the new products the canning certain food packs. However, many questions corrosion, which normal times would approached leisurely and with elaborate ex- perimentation, must grappled with today without waiting for the usual tedious tests. the whole set-up there are some shadow zones marginal areas which must studied and subjected test be- fore the most suitable practice can selected with full confidence. The can manufacturers and packers, well the producers plate, know the problems involved here, and the risk loss consequent upon false step. Thus all parties in- terest are engaged intensive re- search work establish the new program can making and pack- ing foundation facts and experience. (9) Undoubtedly the tremendous growth capacity scheduled for the next months will result large permanent slice business taken away from hot-dip. But, means does this indicate the extinction hot-dip plate, some would have it. already mentioned, the 1943 setup partially stopgap accepted under duress, and there are some shadow zones which would realign themselves just soon the pres- ent emergency over. For in- stance, using the 76,000,000 boxes for 1943, already broken down into processes that the tin shortage dic- tates, theoretical breakdown in- dicative post-war relationships may possibly about follows: Electrolytic coat ..... 36,000,000 boxes Chemically treated (10) Every indication that the 1942 pack primary foods the United States will surpass any pre- vious year. The Department Agriculture goals certain fruits and vege- tables that are expected bring record crops. limit will set cans available for these foods, and expected that 1942 packs tomatoes, snap beans, peas and corn will total over 125,000,000 cases, against about 90,000,000 cases 1941. Electrolytic Program implement the ambitious pro- gram 30,000,000 basis boxes electrolytic plate 1943, every ma- jor tin plate producer must natural- make extensive additions ex- isting coating facilities. Certain the mills have plans still somewhat state flux, regards design equipment and electrochemical technique, but by-and-large seems about new units will con- structed. All these electrotinning lines will handle continuous strip about gage widths ranging in. Speeds will all the way from 200 ft. per min. 650 ft. per min.; 1000 ft. per min. mechanically possible, but current densities the plating tanks must either boiling the electrolyte re- quiring elaborate cooling systems. Or, with certain electrolytes very high current densities sult spongy deposits. Predicat- ing capacities tin weight 0.5 per basis box, the individual lines will have yearly outputs from 750,000 boxes 1,500,000 boxes. course technically possible run plate through with coatings considerably under 0.5 Ib. per box, for instance 0.1 Ib. per THE IRON AGE, April 30, | r | ‘ g 1 | | | § ; t maker Acid VER 3,000,000 base boxes 0.5 electrolytic plate have rolled off this continuous electrotinning line Carnegie. Gary plant. These first views this very compact unit show 32-in. strip moving 350 ft. per min. clip. Economics this unit are very favorable, and nine more stallations are building, which will incorporate features de- veloped this line. The new lines will slightly longer than 140 ft., will plate over 500 ft. per min., and may have melting ment. ABOVE EEDING end the ft. electrotinning line. Steel strip feeding from one two un- coilers (right), thence into shear, seam welder, looping pit, roller guide, drag bridle, electrolytic pickler, brushing machine, and then into the tin plating (extreme left). RIGHT CID tin plating New tin anode hanging chain hoist, used anode floor. Strip can seen passing vertically the tanks, which there are four, each ft. depth. Note circu- lating system for electrolyte. Plated strip may seen upper left. 32—THE IRON AGE, April 30, 1942 7 1 7 RIGHT LOSE-UP view section first the tin plating unit. Strip passing down one tank (right) and through adjoining tank (left). Note electrical contacts the copper rolls, and tops ble, the many tin anodes hanging in- the bath chamber. 4 ° ° ° RIGHT FTER tin plating the through the dragout system (right) high pressure sprays and squeegee rolls, thence through the wire brushing unit, steam dryer and drive bridle. LEFT ELIVERY end the line, with plate piling extreme left. Shown here are the upcut shear (right), roller leveler, flying shear, branner, and piler. The branner adds slight surface oil film. The entire unit one compact sys- tem, with cleaning, plating ing carried out con- tinuously high speed. THE IRON AGE, April 30, 1942—33 | 4 a box. moderate amount such light plate may actually turned out 1943. For the chemical treatment black plate, there are still some un- certain spots the program. Pres- ent plans, however, indicate lines. Some the lines will treat individual sheets continuous basis, and others (such Crown Cork pilet unit) will treat continuous strip. All the lines will use patented process controlled Parker Rustproof Co., and photographs one such line are shown these two pages. Rust proofing bonding treat- ments for steel, developed this company, effect better bond- ing the paint film with the steel surface and inhibit corrosion effected through porosity this film, have served with distinction the automobile industry and for many other types fabricated articles. And, for this new task, Bonderite “K” has been specifically spraying, the steel sheets pass through all operations—Bonderiz- ing, rinsing, and drying—on se- ries rubber rollers with the dual capacity conveyors and applica- tors. Handling entirely auto- matic from feeding packing. This new material, just the case Parkerizing, other Bonderizing and phosphoric acid treatments, must lacquered attain corrosion resis- tance. For use sanitary cans minimizes corrosion and has shown excellent lacquer adhesion. Fairly elaborate equipment re- quired for bonderizing, the cost application pretty high, and the material must naturally lacquered both sides. Bonder- ized film (thickness about 0.0003 in.) cannot soldered, seems definitely limited for packing mildly corrosive foods, and has lim- ited fabricating properties. These factors confine its use end stock. Phosphoric acid treatment seems less satisfactory than Bonder- izing, and other films—as for in- stance, combination chemical treat- ments phosphates, chromates, borates—appear ineffective rust prevention lacquer adhesion; rust prevention lacquer adhe- sion; however, these points have not yet been definitely determined. The electrotinning program will cost the industry something the neighborhood $32,000,000, and the chemical treatment lines will total $40,000,000 ain’t hay, even today. And, since these new facil- 34—THE IRON AGE, April 30, 1942 ities are pretty well scrambled both existing activities, many the companies will finance the new equipment rather than request Gov- ernment aid. The Government, course, will issue certificates necessity assuring amortization. And, although makers electricai and mechanical equipment are load- the scuppers with war work, these tinning lines now carry priority sufficiently high assure completion many the lines early fall and all the lines within months. The breakdown electrotinning and chemical units among the various tin plate produc- ers about follows: United States Steel Corp. Original installation Carnegie- Illinois’ Gary tin mill has been operation for five years, turning out over 3,000,000 boxes plate, used extensively dry packs and can ends experimental wet packs. total nine new units will built; three for Gary, three for Pittsburgh, and three for Fairfield plant Tennessee Coal, Iron and Railroad Co., Birmingham. total six new chemical treatment lines will built, two each for Gary, Irvin and Fairfield. One pilot chemical treat- ment line already operation Gary. Crown Cork Seal Co., Inc. One line operation more for about year, the prod- uct heretofore going exclusively for bottle crowns and glass clo- sures. Another faster unit prac- tically completed. One new continu- ous chemical treatment line being developed. Crucible Steel Co. America One line operation for about five years Midland, Pa., the product going for both specialty applications and general line cans. New 36-in. line soon built. Bethlehem Steel Co. Three electrotinning lines and two chemical lines installed Sparrows Point, Md. Inland Steel Co. Two electrotinning lines and one chemical line installed Chi- cago. Weirton Steel Co. Two electrotinning lines and two chemical lines installed Weirton, Va. Youngstown Sheet Tube Co. Two electrotinning lines and two chemical lines installed Youngstown. Continuous Bonderizing the Gary plant Carnegie-lilinois. This the start the line, with the Dexter feeder foreground handling the stacked black plate per min. rate. The plate runs through rubber rollers (background) immersed Bonderite chemical for sec. (at 155 deg. F.), then through cold water rinse, then through chromic acid (at 185 deg. F.} Jones Laughlin Steel Corp. Two electrotinning lines and two chemical lines installed Pittsburgh. Republic Steel Corp. Two electrotinning lines and two chemical lines installed Niles Works the Warren, Ohio, district. Wheeling Steel Corp. One electrotinning line and one chemical line installed Wheeling. Granite City Steel Co. One electrotinning line and prob- ably one chemical line stalled Granite City, Solutions the mechanical prob- lems encountered wide, speed lines probably require greater ingenuity than the electrochem- ical problems. Nonetheless, great deal effort has been expended the various tin plating baths (elec- trolytes, current densities, tem- peratures, additive agents, anode positions, etc.), and all the electro- tinning lines built can clas- sified roughly according the plat- ing system employed. For instance, the United States Steel Corp. uses acid bath, and the Wheeling line Crown Cork Seal Co., Inc., uses alkaline bath, and licenses have been extended Inland, Bethle- Bonderized Black Plate passes from the rubber rolls the chemical tank into and drying units and emerges onto inspection table (shown here) and stacked. The fine grained phosphate coating (70 mg. per sq. ft.), when lacquered enameled, successfully used bending, crimping, lock-seaming and other can-making forming operations. Bonderite sludge settles out tank, and new chemicals are constantly injected into the system. Not mentioned, course, are some continuous electrotinning lines for narrow strip, for instance strip in. in. wide used for specialty applications rather than for canning. There are some half dozen such lines scattered over the country, for instance one Thomas Steel Co., one American Steel Wire Co., the serpentine pilot line (for plating one both Weirton Steel Co. several years ago, and one building Sharon Steel Corp. The mechanical and electro- chemical problems encountered such narrow lines are comparable with the wide, high speed lines plating light coats tin, which this article con- cerned. hem, Youngstown Sheet Tube Co., Granite City Steel Co. (Stane- lec; stannous tin electrolytic), and Jones Laughlin Steel Corp. United Engineering Foundry Co., working cooperation with Han- son-Van Winkle-Munning Co. uses acid bath, and will build two lines for Weirton Steel Co. (Weir- ite Electrolytic Tinplate). What system Republic will use, what will several units for Britain, far have settled. Crucible Steel Co. Amer- ica flash coats tin with alkaline bath and follows this. with heavier coating acid bath, probably the sulfate type. Nachtman fa- vors the fluoride bath, and pre- viously used such bath Thomas Steel Co. and employs similar technique the narrow line now under construction Sharon Steel Nemours Co., has announced plating bath for strip, designated the halogen tin process (slight- acidic): The company claims that strip steel for containers can tin plated twice fast with less elec- tric power this process the “alkaline” electrotinning method, thereby reducing costs, This rather confusing comparison considerably more enters into the problem than current cost. Pont claims that tin deposited the halogen method can heated with- out discoloration either when the tin plate heated obtain the bright finish required some can manufacturers (i.e., thermal flowing, rather than mechanical brushing), when treated (i.e., baked) during the process apply- ing lacquers enamels. Electrolytic Technique Being large, complex and costly (approximately $1,000,000), the continuous electrotinning unit for wide strip, like the continuous roll- ing mill, must consistently deliver quality product rélatively very high speed with few interruptions for adjustment repair. Other- wise, the economics the process would formidable. Some very wicked mechanical handling prob- lems are introduced as, for instance, guiding the strip and control tension. High-speed pickling almost perfection necessary. Also long lengths strip must passed through electrolytic cells con- stant, uninterrupted speed 250 650 ft. per min., all the time moving close but constant distance away from many plating anodes which are, turn, continu- ously going into solution and re- quiring individual adjustment and replacement (in certain installa- tions). Constant bath temperature and bath analysis are vital. The electrolyte must constantly agi- tated, and heated cooled, the case requires; and, simultaneously, its analysis must maintained the dot frequent chemical tests and judicious adjustments. cer- tain units the solution this prob- lem seems system whereby the electrolyte constantly drawn from the cell travel through auxiliary apparatus which continu- ously and automatically adjusts temperature and composition within tolerance. Constant voltage also most vital, which particularly difficult IRON AGE, April 30, 1 | 4 a q 4 * ABOVE with uncoiler (off left), feeds strip into seam welder (center), through pinch rolls, then threaded tical 8-strand slack producer and from there into sulphuric acid, still tank, strand pickling unit. LEFT tin anodes are sizable hunks metal, ft. long and weighing over ton. They are cast the plant comparatively pure metal, and are stripped and re- placed the bath about once month. The new lines carry about tons tin anodes. faster lines are being built, modeled after this unit Crown Cork Seal Co, Inc., Baltimore. The electrolytic line shown here for the first time handles 32-in. strip 350 per min., and the new lines will take strip 550 ft. per min. separate unit, also shown here, used for thermally re-flowing the tin surface that plate requiring the hot-dip type finish. down the top the tin plating tank, showing the strip entering (left), thence over and under rolls spaced about strands, between each which one-ton anode. Each top roll carries power. 4 (lett ah RIGHT LATED strip (silvery, semi-bright) goes through dragout and washing system, thence into vertical 2-strand slack producer (left center), and (left). Overall length entire line 120 BELOW end brightening line. Coiler (right) feeds strip into pinch rolls, then into 4-strand dock producer, and through vertical gas-fired, tube heating furnace (left) which tin melted and flowed over ‘steel surface, then rapidly water quenched. RIGHT end brightening unit showing vertical furnace the right, 6-strand slack pro- (center), and winding reel The speed this unit 250 ft. per min., and the product has the typical finish hot-dip plate. IRON AGE, Aoril 30, 7 | view the high current den- sities involved (sometimes 200 300 amp. per sq. ft.), and the anode metal frequently perverse go- ing into solution more less rap- idly than metal being plated out. There even are instances when cur- rent conditions are critical that the variation resistance bus changes must balanced minute regulation current de- livered the cells. The electrochemistry tin plat- ing general has shown progres- sive development since the first World War. Tin—like copper and zinc—may plated for industrial purposes from either alkaline acid solution. general, the plating tin from alkaline solu- tion has found applications for the coating articles complicated shape where high throwing power required. The bath operated hot (say 170 deg. F.), and while this has certain drawbacks, also has the merit that assists the cleaning the basis metal, the hot alkaline solution active de- tergent. For the continuous elec- trotinning steel strip, however, frequently stated that these merits the alkaline bath are great importance flat possible make arrangements insure uniform covering with the tin deposit, even with bath only moderate throwing power; also, make adequate provision for the satisfactory cleaning the steel prior plating. Parenthetically, might also mentioned that the alkaline bath has higher bath volt- age and more than double the cath- ode current density acid bath for the same tin deposition. The alkaline tin bath has long history. Industrial development tin plating first started with the introduction plating bath Roseleur 1850, which consisted aqueous solution containing very low concentration stannous chloride and relatively high con- centration sodium phate. This type solution was used extensively during World War when coatings tin found va- riety applications prevent the direct contact steel, brass, etc.. with certain explosives. draw- back the use these solutions the fact that tin present the bivalent form stannite, which tends oxidize stannate, and when this occurs there deteriora- tion the quality the deposit. Although this tendency oxidation 38—THE IRON AGE, April 30, 1942 may suppressed partially the presence reducing salts, e.g., so- dium thiosulphate, etc., compari- son with the solutions used for the electrodeposition other metals, such copper and nickel, the alka- line stannite tin bath was inferior regards stability, well suit- ability, for the production de- posits any reasonable thickness. was found later that more prom- ising results could obtained with alkaline stannate bath. Only about ten years ago was realized that tin can deposited smooth, compact form the latter type solution. Why this had not been recognized previously was probably due the fact that very small proportion tin stan- nite the solution sufficient cause the production deposits spongy tin. With tin anodes oper- ated under normal conditions, some bivalent tin almost invariably en- ters the solution, thereby causing deterioration the deposit. Meth- ods overcoming this defect the bath were, however, possible and number were developed. These ini- tially consisted providing condi- tions that would insure rapid oxi- dation any stannite stannate. Thus, Oplinger and adopted the procedure making periodic additions such oxidizing agents hydrogen peroxide so- dium perborate. Another method* which was proposed later consisted Oplinger and and Patent 1,919,000, 1933. Also Pont Patent 1,841,978. Macnaughtan, “The Electro-deposi- tion Tin from Sodium Stannate Solu- tions with the use Insoluble Anodes,” Electrodepos. Tech. Soc., 1934; Tech. Publ. Internat. Tin Res. Dev. Council, Series the use insoluble anodes which continuously maintained oxidizing conditions the bath and thereby insured the absence stannite ions. This latter method, however, involved depletion the tin con- tent the bath and necessitated tion the solution maintain the metal content. But the most effec- tive method operating stannate solution had been foreshadowed al- ready earlier work carried out Foerster and Dolch* and which indicated that under certain conditions the anode pos- sible insure that the tin will dis- solve entirely the quadrivalent form. the other the develop- ment the acid tin bath which Foerster and Dolch, Elektro. chem., 1910, 16, 599. Naf, “Versuche zur Theorie dey Dissertation, Dres. den, 1911. 830, 1915. tin present entirely the bival- ent form comparatively recent, The particular difficulty that had overcome with this type bath pronounced tendency for tin the form isolated crystals which, upon continued deposition, produce long needles. However, similar difficulty had existed the electro- deposition lead from bivalent lead acid bath, and this had been overcome the Betts’ process for electro-refining lead which was introduced 1902. this process acid lead fluosilicate sciution was used which, with periodic additions glue.to suppress crystal growth, gave compact deposits the metal. When demand arose for electro- refined tin the during World War the method used for the electro-refining lead was adopted.* acid tin fluosilicate bath was employed which peri- odic additions glue were made. This proved successful, and was ap- plied industrial scale between 1915 and 1917. definitely estab- lished the possibility obtaining compact deposits tin from acid solutions. Much work was carried out improve the original solu- tion. Initially, this was devoted the introduction improved addi- tion agents suppress preferential Germany, were prominent this work. 1917 Mathers recom- mended additions cresol while Schlotter Germany was experi- menting with additions ous cresols and phenols. The: American Smelting and Refining Co. adopted the use which was added the form emulsion supplementary addi- tion glue the tin bath. About the same time portion the com- bined and free acid the bath was replaced stan- sulphate and sulphuric acid. 921. Schlotter, British Patent 148,334, 1917. important refining tween 1920 and 1923, when the remainder the combined and free acid was placed acid. 7 q 7 7 | | This appears have resulted from investigations Alexander and the American Smelting and Refining Co. 1923, when the industrial electro-refining tin ceased, the composition the solu- tion use was gm. tin per liter, gm. sulphuric acid, gm. cresolsulphonic acid, with daily additions glue and “Reduction and Refining Tin the United States,” Trans. Amer. Inst. Min. Met. Eng., 1924, 70, 404-440. Modifications have been re- spect the amount and nature the sulphonated aromatic hydrocar- bon used, e.g., sulphonated phenol, benzol, naphthalene, etc., Schlot- ter and instead sulpho- nated cresol. The price these products various countries fre- quently dictated which would used. Additions glue have been maintained, while supplementary addition agent has continued used, and this general has been cresol other coal wood tar distillation product, although lately other organic compounds high molecular weight have been gested. Ferrostan Installation the basis performance date, the United States Steel Corp. (Carnegie-Illinois) Ferrostan (fer- rum iron stannum tin) in- stallation Gary warrants the first detailed description existing and planned commercial wide strip plat- ing installations. great deal experimental work has been carried out this Ferrostan unit, but usu- ally has worked steadily hr. turn, turns week, turning out approximately 1100 base boxes plate per turn, and total well over 3,000,000 base boxes over three years operation. The black plate varies from in. in. width and usually gage. Photographs the Garv unit are shown pages 32-33. The entire assembly about 140 ft. length and consists the fol- lowing units: two uncoilers (coil Weight about 6000 shear, seam welder, looping pit, roller guide, pin hole detector and flying micrometer, magnetic ‘tension 600 electrolytic (10 per cent 200 amp. Per sq. ft.), tampico brushing tin plating bath, drag-out recovery system sprays and rolls, wire brushing ma- chine, steam dryer, drive bridle glorified pinch roll, tension being; about 1900 up-cut shear (cuts out welds, badly pinched and broken plate), roller leveler, flying shear (cuts plate length 1/32 in.), branner, and piler. The tin plating bath phenol- acid solution with glue additions and which based the Schlotter pat- The bath mechan- ically interesting that ver- tical (see photographs) four-pass each pass being ft., the total therefore being ft. Current density the first pass 200 amp. per sq. ft., and the other three passes carry 175 amp. per sq. ft. The plating solution circulated and the temperature accurately controlled (usually cooling) 110 deg. Individual tin anodes are about ft. length, and most important note that the an- odes can changed while the unit operation. Also interesting that anodes can cast from scruff tin (off the tin pots the hot-dip house) and therefore carry some iron. This iron, however, goes into solution and will not plate out acid bath. Schlotter, British Patent 443,429, 1936. Pine and Harshaw Chemical Co., Patent 1,987,749, 1935. United States patent No. 1,824,100, Sept. 22, 1931. Max Schlotter, probably the Continent’s most chemist, also patented many important features bright nickel plating, which process has found wide popularity here the past several years. All American rights the Schlotter tin patents are now held the United States Steel Steel research was one the first perceive the value these patents commercial tin plating, along with Whetzel and George Totten the same company. Original experi- mental work was carried successful research Pittsburgh. Since the war Germany has prohibited the pro- duction hot-dip plate. There are least several electrolytic tin plating plants operating under the Schlotter patent. One nothing more than small laboratory plant used more for wire than for strip. Another the plant Wolff (Ger- many’s largest tin plate maker) Rassel- stein-Andernach the Rheinland. This also only small plant and probably cost more than $10,000. Can plate four six strips one time, perhaps one strip, speed ft. per min. During the past three years Carnegie- Illinois has developed many mechanica! devices, which four patents have been issued and are pending. The equipment originally handled strip about ft. per min., but now the speed about 250 ft. per min., and this soon lifted 350 ft. per min. The plating efficiency kept very near 100 per cent. The bath has capacity about 3850 gal., tin concentration gm. per liter, and the acid concentration about gm. per liter. Glue and other additions are made the bath improve the brightness and structure tin de- posits. The tin can plated with mirror luster, but this finish rather brittle, and shows abrasion marks, finger prints, etc. Therefore, the metal usually plated dull and subsequently mechanically brushed the brushed plate actually con- siderably better than the plate apparently the slight burnishing action which does not remove any the tin. The tampico brushing machine (following pickling) scrubs both sides the strip, the water the brushes being very liberal assure carry-over acid into the tin bath. The dragout recovery system (following plating) has high-pressure jets wash all dragout, the acid which re- covered and concentrated. The scratch brushing machine has metal brushes made fine nickel silver wire. view the fact that this brush working relatively soft tin film only 0.00003 in. thick, not too surprising discover that the most accurate piece equipment the entire line. During early runs there was considerable grief until this was properly de- veloped. precision brushing operation possible only virtue the continuous honing the brush against stone that maintained truly cylindrical all times. Considerable effort was expended the steam dryer, also. The con- tinuous strip first hit with low- pressure saturated steam which condenses the cold plate. then hit with successive steam jets, and the strip emerges from the chamber the surface water film flash evaporated the heat the strip. Inasmuch electrotinned plate carries palm oil the surface, most instances lubricate the dies during can fabrication. Therefore, the branner carries little palm oil impart this oil film, which the reverse the branner hot-dip Little mention made herein relative porosity hot-dip and electro- lytic plate, frequency pin holes, ratings hydrogen evolution test, etc. Much discussion usually centers this prob- lem, not little seemingly somewhat academic view great increase porosity all plate due scratches, bruises ca