The Iron Age 1942-05-07: Vol 149 Iss 19

THOMAS AIDS PRODUCTION MANY VICTORY PRODUCTS During the past decade, Thomas has developed many electro-coated finishes for Thomastrip. When compared with pure metal, electro-coated Thomastrip uses only small percentage the non-ferrous materials. These fin- ishes have been used place pure metals successfully many instances. The coatings will not crack peel. Investigate their production possibilities, deliveries, sav- ings vital metals, and economies your war products. Our engineers will gladly co-operate with you. Write today. FINISH NOT HOT TIN ELECTRO WITH NICKEL, BRASS 4 : j P Here’s job that dishes out nothing but punishment its speed reducers all the time—a job that Cleveland Units have licked consistently since 1929. The largest Manufacturer his Indus- fully engaged War pro- duction—has more than 100 Cleveland Worm Gear Speed Reducers that have never let him down. His statement help avoid For not only must run his plants day and must keep each machine working continuously. Even brief shutdown could stop operation for weeks! Put your peak loads Clevelands. They can “take The Cleveland Worm Gear Company, 3252 East 80th Street, Cleveland, Ohio. Affiliate: The Farval Corporation, Cleveland, Manufacturers Centralized Systems Lubrication Canada: PEACOCK BROTHERS LIMITED WORM THE IRON AGE, published every Thursday the CO. (INC.). Philadelphia under act March 1879. Entered second class matter November 1932, the Post Office yearly North America and South America, Foreign $15. Vol. 149, No. 19. uta leve = | 8 “a he | | MAY 1942 VOL. 149, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° ° ° Managing Editor, LIPPERT News Markets Editor, ROWAN Technical Editor, OLIVER Associate Editors JAMES Art Editor, WINTERS Editorial Assistants Washington Editor MOFFETT Resident District Editors CAMPBELL HERMAN KLEIN Pittsburgh Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis BACON Seattle ° ° DIX, Manager Reader Service ° ° ° Advertising Findle Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Robinson W. J. Fitzgerald 428 Park Bldg., Pittsburgh Warren, Box 81, Hartford, Conn. Johnson, Market Research Mar. Hayes, Production Manager. Baur, Typography and Layout. ° ° 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 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 VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Editorial Observations Traveling Editor Technical Articles Bolts—Material, Heat Treatment, Physical Steel Castings the Triplex Method Single-Bladed Carbide Milling Cutter New Drawing Compound for Nickel Alloys From Locomotives Tanks ..... Nickel Plating Magnesium Decarburization Depth Carbon Tool Steel “Sewing” Alclad Aluminum Colloidal Graphite Cuts Assembly Micro and Macro Structures Gray Iron Lockheed Speeds Press Work Novel Cold Reducing Mill Large Electrodes Speed Arc Welding What's New Material Handling Equipment Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry ....... Personals and Obituaries Machine Tool Activity Non-Ferrous Metals Scrap Markets .......... Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices Warehouse Prices Products Advertised Index Advertisers Copyright. 1942. by Chilten Company (ine.) 220 269 | 100 102 105 174 175 176 178 1 1 Through Peace and Century Service— 100 Years peace and war— good times and bad—Ryerson has served industrial America. every other crisis, continue provide steel meet the emergency requirements our nation war. 54—THE IRON AGE, May 1942 THE RON AGE ESTABLISHED 1855 Observations Traveling Editor some years have been “sidewalk superintendent.” “sidewalk person who peeks through knotholes and watches other people work. This has become such popu- lar avocation that construction companies that surround their building projects with tall board fences, now bore holes them convenient heights accommodate the the field industrial journalism, peering through knotholes vocation and not avocation. And during the past years watching the metal working industry work, have observed many accomplish- ments that are sufficiently noteworthy call for printing ink. have seen little companies grow into big ones due their pains- taking and able making and selling good and needed product. have seen vacant land, over period years, become the sites busy factories. have seen whole industries start from small beginning and these years, become industrial giants that have amazed and startled the world. And perhaps most gratifying all, have seen how uni- versally the men industry have been able increase their stature response the coming opportunity and the growth responsibility. Two years ago, would have said that had about seen the maxi- mum effort and accomplishment. But now know had, then, seen comparatively little. What have seen our industry and our industry during the past two years, and particularly during the past few months, has been astonishing almost unbelievable. have seen new construction undertaken, plants built enlarged, output transformed, capacity multiplied, new industries created such scale challenge the imagination the author the Arabian Nights. have seen industrial America awaken, with all America, the bugle call war after our 25-year dream peace and put its armor and armament. What now taking place our metal working industry great and vast and astonishing inexpressible. leaves doubt what- ever mind the outcome this war. When this hurricane American industrial output, now pouring from our plants and factories, made effective the battle fronts— and soon will be—our adversaries will crushed under such intensity mechanized might man has yet experienced and few men have dreamed of. And the prospect doubly pleasing for spells the vindication our American system enterprise well the destruction the Axis. For this system ours strong enough win the war, strong enough win the peace follow. | | | | | MAY 1942 | ° ° ° | | | | | { | | | | | | | | | | These Plants Want War Work many manufacturers have indicated they have avail- able capacity and are anxious for war work that have asked them prepare brief outlines their facilities, which are listed below. are most anxious place these companies contact with over- pay you get touch with because have ee loade For production 10—24 gage steel prod- ucts including shearing, forming, stamping, drawing, welding, riveting, dip and spray painting and electro-galvanizing. Ade- quate capital and highest credit rating. Large concern, yrs. mfg. machinery equipment, 20,000 sq. ft. mfg. space with approx. 100,000 sq. ft. for storage. Slab millin machine, gear shaper for internal external spur cutting, and spindle lathes, vertical boring mill, gear hobber, milling machine, sensitive, radial and vertical power drills, tapping machine, planers, cutting saws and electric welding machines. Have men three shifts, also training classes. pally war work sub-contracts for me- dium size parts. Ohio mfgr. decorated metal dry package and dis- displays. plants, space 370,000 sq. ft.; 250. Dry package assembly line from Automatic and hand-fed punch presses, complete decorat- ing and baking equipment, with facilities for coating baking sheet metal. Litho- graphing, engraving and screen processes. Large Mid-west spring bed mfr. fireproof building with over 40,000 sq. ft. fl. space, located railroad siding. Plant includes full line punch presses, coiling machines and various other equipment used making bed springs. coilers for making special springs for aviation industry. Also two two lathes, milling machine, drill press, grinders, heat treating facilities and misc. machine shop equipment. Longestablished Mo. fabricator heavy sheet metal, light plate and structurals. Equipment includes ft. and ft. press brakes, gate shears, ft. (plain and corrugated), punch and drill presses, gascutting equip- ment, many years experience Govern- ment work and currently occupied sub-contract basis. one shift only. known Mo. mfgr. employing 250 including approximately men eng. staff, has 75,000 eq. ft. floor space for seven day week operation. Equipped form standard and special shapes from sheet steel, channels, angles and Z-bars. Complete machine and welding shop. prime” contractors Government agencies order that America will quickly attain maximum Large steel furniture mfr. located two railroad sidings. Plant space over 100,000 sq. ft., employs 150 200 men one shift. Complete facilities for handling gage steel sheets, steel stampings, light gage tubular and angle iron fabrication. All types finishes, including solid colors and wood grains. Plant has com- plete machine paint shops with am- capacity punch and drill presses, enders, lathes, grinders and shears, hand and power brakes and welders. Have suc- cessfully completed great variety war work contracts. Middle West stove concern, approx. 200,000 sq. ft. working space with complete equipment for stamp- ings, spot welding, drilling, brazing, and assembly parts, including finishing bake ovens. Nationally known implement mfr. (Ind.) desiring direct sub-contract war work, with complete equipment for metal forming and small drop forgings, including punch pressesand shears, drop and trip hammers, threaders, forging rolls, end grinders, eye- benders, bull dozers, lathes, and forging furnaces. Ohio, 50,000 sq. ft. fi. space, thoroughly experienced war work, capacity for sheet metal stamp- ings, light structurals and sheet metal fabrication. Ohio mfr. having 66,000 sq. ft. available plant floor space and employes desires war contracts. Plant includes double end punch and shears (200 tons pressure), single end punch and shears (100 and tons pressure), single end punch presses tons pressure), belt-driven drop hammers (1,000 bull in. in. stroke, presses, lathes, drill presses, boring machines, and heating furnaces. Ill. mfr. range boilers, hot water tanks, 27,000 sq. ft. fl. space, property adjoining available for expansion. Average number emp. 60. Complete facilities for welding and fabri- cating ga. in. sheet metal. Hand operated and automatic electric welders. Have facilities for galvanizing, kettle size in. ft. long and ft. deep. Will- ing convert plant war production. war production. any the companies which you are Even the type plant you not listed, have war work place, wire give you the names and addresses are continuing assemble information additional plants. Large Mid-west stove mfr. with complete facilities including 300 presses ranging from 400 ton triple- acting hydraulic small punch presses. All types spot, seam and portable elec- tric welders, automatic plating, japanning equipment with conveyorized ovens, com- plete porcelain enameling plants with con- tinuous type furnaces. Grey-iron foundry. Will send experienced engineers discuss direct sub-contracts for war work. Large heating, ventilating and air conditioning company Ill. with complete facilities for welding all types including electric, oxy- acetylene, stationary and gun type spot Shearing and braking cap. gage ft. wide, and machine equipment. Up-to-date finishing depart- ment and large bake oven. Approx. 100 employees. Modern mfg. plant (Wis.) with complete equipment and trained personnel for fabricating sheet steel products —32 gage. Over 750,000 sq. ft. fl. space well lighted and venti- lated brick and steel buildings. Excep- tional opportunity for mfg. and assemb lines. uipment includes 117 presses, shears, hammers, drills, welders and complete machine shop. Sub- contract business given careful attention war contract division this company. Ind. sheet metal manufac- turer with 800 employes and 450,000 square feet plant floor space has air presses, double action presses, hydraulic press, blanking presses, and punch presses. Complete welding and painting equipment and all types assembly. Have been making bottle coolers, sinks, cabinets, automobile and jeep bodies, Bicycle accessory manufacturer Ia. Employing (one shift) has available facilities for addition- war work including stamping and drawing presses, automatic screw ma- chines, lathes, drill presses, welders, shap- ers, grinders, benders, and riveting ma- chines. Complete Cadmium plating plant. One story fire-proof building steam heated, glass enclosed. Located wholesale manufacturing district. Write wire for names and addresses companies. Dearborn Street, Offices: Milwaukee, Detroit, St. Louis, Kansas City, New BOLTS —Material, Heat Treatment OLTS, from standpoint, are fastening de- vices, and steels used for fastening devices are those which must have moderate de- gree plasticity. Plasticity desirable because unusual load applied tending disconnect the two members held together the fastening device, better that their severance gradual rather than sudden. This being the case, bolts are rarely made from high carbon steel but usually from low and medium carbon steels, heat treated produce plasticity. earlier days, bolt heads were forged. Later this developed into more elaborate machinery for hot heading, increasing considerably the rate production. The high- est degree development this hot forming method machine that heads and roll-threads the heated blank one cycle. Hot formed bolts are also made from and Physical Properties critical analysis carbon and alloy steel cold formed bolts and carbon steel hot formed bolts given herein. Herein, part one two part series, covers cold formed, low and medium carbon steel JAMESON Metallurgist, International Harvester Co., Chicago bolt materials and their approxi- mate tensile properties. tion with Table that the physical properties these materials will vary considerably, depending upon their austenitic grain size and the material receiving further heat treatment. The most obvious way increase the strength hot formed bolt increase the car- bon content and secondly the man- ganese content the material. Table shows typical hot formed TABLE Typical Hot Formed Bolt Materials* and Approximate Tensile Properties ! Physical Properties Tension Type Steel cation Sq. In. Sq. In. Per Cent Per Cent Standard ASTM 0.500 in. Test Bars 99,000 = = = = = = = THE IRON AGE, May 7 e "] n ig Pp t- ° ° ° ° y. 140,000 130,000 0.08 0.38 0.59 Percentage carbon cooling rates employed after hot heading. However, using the yield point deemed the most im- portant property this type bolt, will noted that: (1) With the low carbon steels, C-1017 vs. C-1018, 27-point in- crease manganese content in- creased the yield point 5000 per sq. in. (2) The bessemer steel, B-1112, had yield point 6000 per sq. in. higher than the equivalent sulphur- ized carbon steel, C-1116. (3) C-1116 and C-1117, the increase 0.05 0.10 0.15 IG. The physical prop- erties bolt steels plotted against the car- bon content. Elongation reduction ofarea, perc 1117 steel increased the yield point 6000 lb. per sq. in. (4) With the medium carbon steels, C-1038 and C-1041, 9-point carbon increase raised the yield point 5000 lb. per sq. in., while be- tween the low and medium carbon steels, C-1018 and C-1038, 18- point increase carbon increased the yield point 11,000 lb. per sq. in. Data Edwards showing the effect increasing carbon and manganese contents the tensile strength steel are given Figs. and The increase the tensile strength various steels due the addi- tion nese various carbon steels. 030 Percentage carbon 58—THE IRON AGE, May 1942 The additions of-carbon and man- ganese would cease when such addi- tions reduced the plasticity the tice, however, the limitations would governed the ease with which the bolt could threaded. should understood that the ma- jority hot headed bolts are cut threaded the cold cause this, sulphurized steels, which are relatively easily threaded, are used for hot headed bolts. The stock for hot headed bolts pur- chased hot rolled bolt rounds, held outside diameter limits with tolerances the minus side. This done insure the correct basic major diameter the Cold Formed Bolts The most popular method manufacturing bolts cold head- ing, the material used being the form cold drawn wire. dis- cussion the material can conveniently divided into two sec- tions, namely low carbon and medium carbon. The advantages using low carbon steel are that the initial cost the material, and the cost heading, trimming, and threading, are considerably less. The disad- vantage that the tensile strength not great can obtained from medium steel heat treated. basic open hearth, semi-killed steel conforming the American Iron Steel Institute’s specification the following sis the most commonly used: Carbon 0.15 0.20 per cent Sulphur 0.050 per cent maximum Manganese 0.60 0.80 per cent Phosphorus 0.040 per cent maximum the utilization this ma- terial, the basic principle one retaining the high tensile strength the cold drawn wire. The effect cold drawing the physical properties 0.27 carbon steel illustrated Fig. The limitations placed using wire drawing means in- creasing bolt strength that suf- ficient plasticity must retained the wire that can used the cold heading operation. Therefore, for all practical pur- poses one draft all that can employed. properly employ this principle retaining the effect the cold working, maximum and ‘ 8000 °, ma- cut Be- ded, The nds, eter nus the Tensile strength, sq.in. Elongation reduction area, per cent Hot 9.1 226 283 443 104 Reduction area drawing 3—The effect cold drawing the tensile bolts 0,000 Colddrawn Cold 950 1000 1050 Process annealed deg. wire, formed IG. 4—The tensile strength cold headed and process annealed and Na- properties 0.27 per cent carbon steel. minimum tensile strength specifi- cation limit must placed the wire. now use Tensile Strength, 2in., Per Area, Per Cent (Min.) (Max.) (Minimum) (Minimum) 70,000 90,000 15.0 50.0 After cold heading, the bolts are given process anneal return some degree plasticity the highly cold worked head the bolt. The threaded section the bolt, which represents its tensile strength, also somewhat reduced this process anneal. tration the process from the physical standpoint shown Fig. re-crystal- lization visible when cold formed bolts are process annealed 1000 deg. complete illustration the effect annealing 0.18 per cent carbon steel, cold reduced per cent one dimension, The statement that process an- neal necessary restore plas- ticity the cold worked head the bolt subject modification the extent that special pre- cautions are taken, such using heavier gage wire and later extrud- img the bolt blank the threaded section, process anneal may not necessary. Thus, bolt having tensile strength 100,000 Ib. per sq. in. may produced cold work and safely used. Medium Carbon Bolts For clarity presentation, the medium carbon bolts can further broken down carbon steel and alloy steel bolts. The essential dif- ference that the more popular bolt 34, 7/16, and sizes, TABLE tional Coarse bolts, containing 0.17 per cent carbon. carbon steel does not have the hardness penetration produce completely hardened the bolt. Thus, bolts made from carbon steel not have high tensile value for the same surface hard- ness. might suggested that more severe quench might used. This, however, often results cracking the bolts that for all practical purposes, undesir- able aim producing maximum hardness penetration this means. The most used analysis car- bon steel for bolts is: 0.30 0.45 per cent; manganese 0.60 0.90 per cent, and silicon 0.10 0.30 per cent. There una- nimity matter carbon ranges within the points quenching mediums austenitic grain size specifications. For the purpose discussion, the practice one manufacturer will used. With this manufacturer there are two Chemical and Austenitic Grain Size Specifications Carbon Steel Bolts Manganese Silicon Over 0.430 0.32 0.38 0.60 0.90 0.15 water C-1034 THE IRON AGE, May the dis- and low ad- gth eat led na- rth cal ing in- uf- Cold reduced, per cent deg. 1000 deg. 1300 deg. 1400 deg. IG. 5—The effect process annealing 0.18 per cent carbon steel, cold reduced, per cent, various predetermined temperatures. Nital etched and magnified 300 diameters. specifications set up: One for water quenching and one for oil quench- ing. The use these quenching media based size, illustrated Table II. Wire purchased the form cold drawn wire diameter tolerance 0.002 in., the toler- within any one coil being within total 0.001 in. These desirable conditions are obtained drawing through carbide dies. The wire size tolerance quite important with this material the life heading dies more important than the cold heading low carbon steel wire. Die life 1,000,000 pieces per solid 60—THE IRON AGE, May 1942 die not uncommon using low car- bon wire, whereas 250,000-pieces quite good using medium carbon steel wire. produce good die life, the finish the medium carbon wire also important. Finishes are usu- ally produced pickling, rusting and drawing with aluminum stear- ate some other similar acting material. The die life can in- creased per cent when careful attention paid the wire finish. maintain good die life and further insure uniform heading properties, medium wire treated before cold drawing either annealing above the criti- cal (A.) range, 1650 1700 deg. F., annealing below the critical range, 1200 1300 deg The first treatment produces pearlitic structure and the second spheroidized structure, illustrated Fig. The second treatment more time consuming than the first, but the relative merits the two treatments there doubt that the spheroidized superior heading properties. How- ever, the case bolt heading, the high temperature anneal good enough. From frequent tests, difference heading die life was detected, but said some that the response heat treatment different. Again, from many tests, has been concluded that practical difference encountered. The microstructure the bolt wire will naturally affect its physi- ‘al properties. The wire usually purchased maximum tensile requirement and minimum elon- gation reduction area require- ment. typical requirement follows: Tensile Reduction Hardness Wire Strength, Area, Rockwell In. (Maximum) (Minimum) Over 0.430 105,000 Editor’s Note: Next week the author will conclude this discussion bolt steels, dealing with heat treating carbon steel bolts, and the use alloy steels the manufacture bolts. Annealing above the critical range (1680 deg. produces the pearlitic microstructure similar that shown left, while annealing below the range (1300 deg. F.) produced the spheroidized structure the right. The etch- ant used and magnification was 300 diameters. ° ° GREGG Executive Engineer, Whiting Corp., Harvey, triplex method for the continuous production steel castings relatively new development that holds great prom- ise for the steel casting industry. This method involves the use the cupola, the converter and the electric furnace (see Fig. 1), hence the designation “triplex.” The de- velopment this process was the result demand for metal lower carbon than could produced with the cupola. matter what material charged into cupola, very difficult obtain carbon content much below 2.75 per cent. When the demand arose for low- carbons, and this was especially the case connection with so-called copper-silicon steel having carbon content 1.50 per cent, the method adopted was mix cupola metal containing about per cent with blown metal containing about 0.05 per cent. These two metals, mixed proportion give the desired carbon, were transferred elec- furnace for distribution molds produced traveling con- veyor. When the large demand for steel castings developed result the war effort, this method was modified produce steel with car- bon ranging from 0.25 0.50 per cent. This composition was ob- tained blending converter metal with cupola metal suitable pro- arrive the desired percentage carbon. producing steel the triplex method, the cupola charge usually consists steel scrap, plus Silicon-bearing material, such Steel Castings the Triplex Use the triplex method, which combines the cupola, the converter and the electric furnace, for producing steel with carbon content lower than that obtainable use the cupola alone, described this article. per cent ferro-silicon, silicon briquettes silvery pig iron. The temperature the converter steel controlled the percentage silicon the cupola metal. With per cent the cupola metal, the converter metal will have tem- perature 3000 deg. more. Cupola metal desulphurized the ladle prior blowing, and with proper procedure and the correct amount alkaline material, sul- phur can readily held range 0.25 0.04 per cent. Ordinarily the steel deoxidized and recarburized additions cupola metal, ferro-manganese, fer- ro-silicon and aluminum, before delivered the electric furnace. The electric furnace this case operates heated distributing unit and power consumption very low the metal practically finished before delivery the elec- tric furnace. customary adjust com- position and temperature the electric furnace and alloys are required, convenient add them here. desirable have about half hour’s supply steel the electric furnace all times. When this process was first put into operation, some difficulty was experienced maintaining neu- tral non-oxidizing slag, which highly essential, because oxidiz- ing slag will result loss car- bon, silicon and manganese. Content Check Carbon composition regularly checked samples taken from the electric furnace each time con- verter heat added. This done conveniently with Carbometer Carb-analyzer. The automotive gray iron foun- dries for many years have used continuous methods molding, pouring, etc. Molds are made machines and placed moving conveyor and while the convey- cores are set, molds are closed and poured, cooled and finally de- livered shake-out machine. Obviously continuous produc- tion and pouring scheme presup- poses continuous supply molten metal. For gray iron, the cupola furnace supplied this need ad- mirably because continuous melter. The melting rate can synchronized with the metal re- quired the mold conveyor very exacting degree. Continuous operation makes possible very large economies floor space and labor, and this system has been generally adopted all gray iron foundries THE IRON AGE, May | eg. cal ond ted 1 ore but hat has ife ed. si- lly re- or | on q 1 producing large tonnages long- run castings. The benefits continuous opera- tion have not been available manufacturers steel castings, primarily for want continuous supply molten steel. The operat- ing cycles for open hearth and electric furnaces range from more hours, and even the converter process (which has 20-min. cycle) the demand for con- tinuous steel not fulfilled. The war demand for steel cast- ings has been conservatively esti- mated being three times greater TRANSFORMER HOUSE ELECTRIC FURNACE SIDE-BLOW CONVERTER BLOWER SKIP HOIST CHARGER BLOWER than present capacity. would seem that the simplest and most readily available method increase electric furnace capacity would adopt the triplex method in- stalling cupolas and converters supply molten steel the electric furnaces. This would have the additional advantage flexibility and, under some circumstances, might practical shut down the electric furnaces and use straight converter steel. This might very well hap- pen when the war demand for large tonnages comes end. the present time converter steel has not been approved for ordnance castings made under Spe- cification QQS-681-b, although sev- eral well known foundries have been making ordnance castings un- der Specification QQS-68l-a more difficult specification), and meeting all requirements, both chemical and physical. The Ord- nance Department recently has ap- 62—THE IRON AGE, May 1942 CONVERTER OPERATORS PULPIT proved the triplex process for the production all types ordnance castings. Physical Properties Typical physical properties steel produced this process are follows: Tensile strength, per sq. in. 80,000 85,000 Ib. Yield point, per sq. in. 42,000 48,000 per cent. Reduction area 42% per cent. Cold bend 140 deg. 180 deg. There are several variations the triplex process which may worthy consideration: (1) the converter installed connection with basic-lined elec- tric furnaces, possible use practically any kind charging material, even cast iron. The cupola metal would then desulphurized the ladle prior blowing, and the blown metal would dephos- the basic electric fur- nace. This would make available high phosphorus material which present not usable any acid steel-making process. (2) Another, and perhaps more promising method operation, in- volves the use the dephosphoriz- ing method* developed Gordon Yocom Wheeling Steel Corp. after blowing, dephosphorized the ladle treatment with com- bination lime, fluorspar and mill scale. this way the removal any desired amount phosphorus (up per cent) readily ac- complished. The metal, after this treatment, highly oxidized condition and requires treatment the electric furnace, either acid basic lined, remove excess oxygen. *See Ace, Oct. 31, 1940, Also, see “Rapid Metallurgy War (3) the Yocom method adopted for phosphorus removal and the metal transferred basic electric furnace, will possible Typical layout the various units re- quired produce steel for castings the triplex method. operate with single slag, whereby sulphur will removed, making unnecessary desul- phurize the cupola metal prior the converter operation. The triplex process has many ad- vantages. There large saving power—the electric furnace when operated holding unit, con- sumes only about kw.-hr. per ton with acid operation, but considerably higher for basic op- eration. Power Needs Reduced the Yocom process for dephos- phorizing combined with basic electric operation, the power con- sumption will reduced least per cent reason the advan- tage operating with only single desulphurizing slag. course, low-phosphorus material able, the most economical arrange- ment for triplexing operate both converter and electric furnace with acid lining and use the £ furnace holding distribut- ing unit only. the present time many iron foundries are considering the in- stallation steel making equip- ment because the fact that thus far cast iron has played relative- small part the war program. should remembered, however, that considerable experience re- quired for the manufacture steel castings and that the melting de- partment involves but small part the equipment necessary con- vert iron foundry into steel foundry. The method gating and riser- ing for steel castings differs radi- cally from iron practice; the sand for molding and core making must Single-Bladed Carbide Milling time when manufacturers standard milling cutters are unable keep with the de- mand, McKenna Metals Co., La- trobe, Pa., announces method which simple facing cutter heads may made almost any shop. Due its high speed cutting, this single-bladed Kennamill, em- ploying Kennametal tungsten tita- nium carbide tools, will often work more efficiently than standard cut- ter requiring many high speed steel blades. Designed with large negative spiral angle deg. and positive hook deg., this cutter mills steel efficiently because Kennametal does not gall mit the adherence steel chips the hard, strong tool tip which “skids” the steel chip off smoothly these angles. For roughing, with cuts have much higher refractory value, and the cleaning department will require much additional equip- ment. addition this, special equipment required for heat treating and annealing, and last, but not least, trained metallurgi- cal personnel imperative for the control all the steel-making and heat-treating processes. Some fear has been expressed that the war demand will build excessive capacity for steel cast- ings which would unnecessary and unused after the war demand ceases. Such considerations must forgotten the present time, first interest today win the war, and steel castings are one the vital necessities supply tank in. deep, 35-deg. negative helical angle and 15-deg. positive hook 12-in. diameter cutter head has been found work efficiently. For light finishing cuts parts, tank armor, gun carriages and other munitions. The triplex process, while re- cent development, successful operation today and under consid- eration several important pro- ducers. one case manufacturer has been through the triplex process, obtain production four times the normal rated capacity electric furnace. Such results certainly warrant careful consid- eration steel producers, especial- the triplex process represents considerably lower investment for new equipment and can put into operation much shorter time than many other method’s avail- able for increasing production. Cutter helix deg. with 20-deg. posi- tive hook angle most efficient. The hook angle should less smaller diameter head. Kennametal cutters should run 300 600 ft. per min. pe- ripheral speed, with table feed 0.008 in. per rev., depending the material being machined. 6-in. diameter head gives about in. per min. table feed 380 r.p.m. (600 ft./min. cutting speed). Clearances should kept minimum and only slight radius used. cool- ant should used impos- sible keep the cutting point flooded the speeds employed. The Kennametal-tipped blades can removed from the cutter heads and reground quickly, im- portant advantage over standard cutters, which require removal the entire head from the machine, with consequent loss time. New Drawing Compound for Nickel Alloys ICKEL alloys can now drawn, stamped formed, and then annealed without clean- ing, using dispersion Digly- col Stearate water. Diglycol Stearate made Glyco Prod- ucts Co., 230 King Street, Brooklyn, white wax-like solid dispersible water, has melting point 124 129 deg. will fire off completely temperature 400 oxygen hydrogen. concen- tration per cent applied spray usually sufficient lubri- cant for drawing and stamping, though per cent concentrations are sometimes employed. Concen- trations less than per cent can generally used replace the sulphonated oils used lubricants stamping. THE IRON AGE, May 1942—63 5 . 7 > \ ar | | { { 4 7 From Locomotives ANK production about complex manufacturing job can encountered. Con- taining over 30,000 piece parts, the M-3 medium tank and its successor, the M-4, are highly specialized ma- chines that must produced close tolerences mass produc- tion basis, although tank production did not begin that way. Not the least the difficulties was that there was very little prior art this type heavy machine con- struction. Yet when the Battle France demonstrated beyond doubt the importance the tank mechanized land warfare, the Ord- nance Department the Army with the cooperation the OPM that fateful June 1940 sought manufacturers who either had the facilities the “know how” produce these mobile forts. retrospect, appears now that they worked both ends against the middle. that date, railroad car build- already was making the light tank and steadily increasing its out- put. seemed natural therefore that for heavier vehicle, the War 64—THE IRON AGE, May 1942 FRANK OLIVER Technical Editor, The Age Department and the OPM should turn the locomotive builders, which were just beginning show some signs activity after hiber- nating through the long, lean de- pression years. Such manufactur- ers make highly specialized ma- chine close tolerances, but not mass production basis. fact, the reverse condition true; through customer policy, prac- tically every locomotive built was custom job suit the ideas particular railroad. the same time that contracts were being ne- gotiated with these builders, the OPM turned the other direction and signed the Chrysler Corp. produce the M-3 medium tank. The problem had many new and un- familiar slants Chrysler did the locomotive builders. fact, the problem was dif- ferent from its regular line pro- duction that Chrysler chose build (at government expense) en- tirely new plant and equip with the latest production machinery. That, course, was the days when automotive production was the credit the locomotive build- ers that they got going quickly existing equipment, although ulti- mately they bolstered manufacturing facilities with new machine tools fast they could obtained. Locomotive builders had the “know how,” this important ex- tent—they were experienced riv- eting, machining and welding heavy steel plate and steel castings; they had the large, heavy machine tools for big work and equally important, the necessary crane facilities, and they were versatile handling wide variety operations. Fur- thermore, particularly since the adoption roller bearings, they were used working close toler- ances heavy work—quite dif- ferent proposition hitting close tolerances light parts. And last- ORCH ting sprocket gears shape being con- trolled tem- plate mounted the table the rear. q | 1 | ° ° ° . j > ly, they are great improvisers tooling when the quantities are relatively small and the tolerances relatively tight, considering the size and weight the work. They had assembly comparable the power driven ones found the au- tomotive industry, but the principle spot station type assembly well known both locomotive and railroad car builders, and this primarily the type assembly line found the modern tank arsenal. This story concerns itself with the part that the American Loco- motive Co. played this race against time, because was among the first commercial companies build pilot model the M-3 me- dium tank and get into line pro- duction this model. The original tank order, calling for one and half tanks day, was given the form letter intent after conference with William Knud- sen, OPM, July, 1940. the time the formal contract was signed with American Locomotive Co. November, production was already under way and all the addi- tional machinery had been ordered. The first pilot tank was completed April 19, 1941, and two months later these tanks were regular line production. The program has been greatly expanded since then. the American Locomotive Co., even though the contract was “cost plus” free basis, there were some challenging elements present that brought forth the competitive spirit the operating personnel. From the start, Robert McColl, vice-president charge manu- facturing, set definite objectives that his company should build the first tank, the best tank and the least cost. The company knows that has achieved the first goal, be- lieves making the best tank and hopes that the time cost comparisons are made, will shown making the lowest cost tank. shall seen, the latter goal one that being constantly striven for. Long believer team work and “stars,” the company immedi- ately set 10-man committee, chairmanned Mr. McColl. this committee were members his general manufacturing staff, such mechanical superintendent equipment supervisor, the pro- cess engineer, piece work supervisor and some the divisional super- intendents, well the manager the main works. The committee started work spending week Rock Island seeing how the M-3’s immediate predecessor was being made. These men studied the parts, operations sheets, tooling and actual produc- tion, bearing mind, course, that the arsenals are primarily ex- perimental production shops and that many methods could im- proved upon when the production quantities involved became large enough warrant more elaborate tooling set-ups. When the committee got back the plant, series round table conferences began that continued THE IRON AGE, May q Loco a Motiy m tank 3 e ° 2 at th T- rs n- m | | | for three weeks. these confer- ences, which often lasted far into the night, many important ques- tions were decided. First these was what parts the tank were manufactured and what parts subcontracted. the start, certain items had been designated the arsenal “free items, like transmissions, engines, guns (but not gun mounts), track shoes and other specialties for which pro- duction had already been arranged the Ordnance Department. Parts like armor plate, would obviously have come from steel mill, but the company had the option ma- chining the plate edges and drilling the rivet holes having the job done the supplier. The locomo- tive company chose the latter meth- od. Similarly, when the cast steel hulls came into the picture, the company bought these from two suppliers with all the necessary machining operations already per- formed. Once the parts that were made the company’s own shops were decided upon, then became necessary for the committee de- termine the sequence operations each piece, select the equipment which the operations were performed and decide upon the gen- eral features the tooling. simplify this enormous amount detail, each member the commit- tee, during the arsenal visit, had been assigned assembly unit for which was entirely respon- 66—THE IRON AGE, May 1942 FTER the teeth the sprockets have been roughed out with automatic cutting tools, they are accu- rately milled final shape this Newton planer-type miller. Thirty blanks are stacked the fixture with man- drel supported centers the manner shown. index plate the far end the mandrel governs the spacing between the teeth. sible. other words, became the chief expeditor project engi- neer for that particular unit, al- though each man could draw upon the experiences and ideas the en- tire group deciding matters tooling and the like. The arsenal furnished complete drawings and operation sheets, but the latter were used largely guides point departure. Obviously, al- ways easier improve upon some- thing already set than strike out anew. For each part, two decisions had tooling: How the job 100 per cent existing equipment, and secondly, how best either existing equipment newly pur- chased machine tools. will remembered that one the com- pany’s main objectives was the first deliver acceptable pilot model. Frequently, when new machine tool was ordered, duplicated many machine tools al- ready the shop, but allowed these new machines, which were bought for the account the De- fense Plant Corp., assigned tank work only, whereas many the older machines still had locomotive work part-time basis. Such new machines included horizontal boring, drilling and mill- ing machines, big vertical boring mills and vertical turret lathes. fact the number boring mills in. capacity and over, bore defi- nite relationship daily output, roughly equal. Some older machines were adapt- for tank work adding special attachments. large vertical spin- dle miller, for example, was con- verted into contour miller the addition complicated hydraulic and electric duplicating device which permits the table feed both directions controlled template. The follower pin en- gaging the template through elec- tric devices controls the amount and direction rotation hydraulic motors driving the cross and lon- gitudinal feed screws. Since the job was started ex- isting eauipment, tank work will found scattered through the various shops the main plant. Riveting operations are done the boiler shop, for example, but welding the tank bogey wheels done the tender shop because some the machinery for forming light plate was already there. Some machinery | 1 i ‘ ° ° t | | al- wed vere De- rned ided nill- ring put, operations are performed the cylinder shop and others the wheel and axle shop, largely because the existing equipment was able there space could found for additional purchased equipment. that extent, “line production” methods, such were adopted the completely new Chrysler ar- senal, are absent here. result, certain amount material back- tracking unavoidable, and can excused the ground that the company got with the job record time and yet was able meet the obligations its regular customers who needed motive pow- haul the expanded shipping programs connection with the defense effort. the selection this machinery and the tooling thereof, representa- tives machine tool builders and dealer organizations were called and were very helpful making recommendations regarding meth- ods and tooling. About 200 new machine tools all were purchased. the main plant, all jig and fixture design came under the di- rection small tools supervisor, who, incidentally, was member this tank committee. The program, however, called for more jig and fixture work than ordinarily en- countered locomotive work, this department has been greatly expanded into real tool engineer- division. the other hand, railroad equipment builders lot, faced with problems high PERATIONS and the turret rotors for the 75-mm. gun are carried out these Bullard vertical turret lathes. accuracy and low production vol- ume, have had use considerable ingenuity evolving low-cost tool- ing set-ups. The new situation tanks allowed full play for this type ingenuity with much greater freedom from the economic side, since the tooling costs could spread over much greater number units. Actually, what happened was that number jigs and fixtures were improvised first order “get going,” then improved time went and particularly new equip- ment was delivered, many cases especially tooled. fee type contract, the incentive maintaining low costs lost. fact, ordinarily the incentive reverse; the higher cost, the higher the fee. must remembered, however, that the company set one its own goals the distinction being the lowest cost contractor the group. costs were under control from the start. were broken down into straight labor, machine burden rate, super- vision, tooling costs and general overhead. Every job had have time estimate made since the shop workers are all paid piece rate system. methods and tooling were improved, there were, course, revisions made these time estimates. matter fact, there has been constant improvement both methods and costs since the start. big factor this regard has been the experience the com- pany’s Canadian subsidiary which has been producing tanks for the British for much longer period. Many improvements methods have been directly *transplanted from Canada. Integrating tank production with locomotive production was another problem that had licked. Ex- cept for the big castings, parts are sent through the machine shop lots 35, which means that for many operations given machine shop only working part time tank parts, that with the exception the new machines pur- chased behalf the government for this job. This meant that the planning and routing department had plan machine loadings combination with locomotive manu- facture. This has proved one the difficult jobs, but here again the experience the Canadian sub- sidiary has been most helpful. Flow charts, for example, have been de- vised which show the progress the work through the shop; the cu- mulative man-hours expended and whether the part ahead behind schedule. This graphical control THE IRON AGE, 1942—67 4 § 4 ° ° ° apt- cial pin- vice en- and ex- ous iler system has been transplanted the American plant. During the late fall 1941, steps were taken produce portion M-3-Al tanks, ultimately the M-4 tanks, with cast steel hulls place riveted armor plate construction. first glance, would appear that the use castings would speed assembly operations. the loco- motive plant, however, this change actually adds additional opera- tion the assembly line, that welding the hull the sponson plates. All riveted hulls are made the boiler shop, which being relieved that much work the shift gradually made cast armor steel hulls. indicated previously, machining work done the big steel castings. Like every other plant getting into war work, the company was faced with rapid rise the num- ber its employees. the case the railroad equipment makers, the problem was accentuated since their activities had shrunk ex- tremely low levels during the de- pression years. American Locomo- tive Co., for example, built only one locomotive all 1932. But the defense program started, loco- motive orders began come through the biggest volume since 1929. Fortunately, the American Locomotive Co. had maintained nucleus organization throughout the lean years, but had build largely the basis hiring green help, many them recent high school graduates who had never been inside shop before. for- mal training program was set up. Instead each new man started work observer alongside experienced hand. The company has been agreeably surprised the re- sults this program. Most these boys appear have large amount mechanical aptitude and have been quick catch the new work. Nickel Plating Magnesium Alloys METHOD for electrodeposit- ing nickel magnesium alloys described paper presented before the general meeting the Electrochemical Nashville, Tenn., Loose, metallurgist, Dow Chemical Co., Midland, Mich. The process consists series steps which the basis metal first etched slightly chromic- nitric-sulphuric acid bath, then treated hydrofluoric-nitric acid solution deposit fluoride film prior plating with nickel from nickel borofluoride bath. The effect concentration the various constituents both the pretreating and the plating baths discussed. Both nickel fluoride and borofluoride plating baths have been studied extensively the effect co