The Iron Age 1942-05-14: Vol 149 Iss 20

3 MAY 14, 1942 4 oh ope 9 Quiet Crane reduce and Wear WHITING CRANES The load onthe bridge drive re- crane kept squarely the runway without binding. doesn’t take engineer know that noise means wear and tear. Quiet operation can only come from careful construction. Whiting cranes have heavy duty anti-friction roller bearings running flexible couplings for power transmission tread load axle bearings—features that assure long life and low maintenance cost. Whiting cranes are the quietest cranes you ever heard. Capacities from one 400 tons. Also electric hoists from tons. Whiting Corporation, 15601 Lathrop Ave., quality cranes for over fifty years. SEND FOR BOOKLET “How Write Traveling Crane t i tear. é tures the MAY 14, 1942 VOL. 149, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° Monaging 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 Milwaukee Birmingham SANDERSON Toronto, Ontario BACON Seattle ° ° DIX, Manager Reader Service ° Advertising Staff Emerson Findley Uni nion Bldg., Cleveland Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Robinson Fitzgerald 428 Park Pittsburgh Warren, Box 81, Hartford, Conn. Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout ° ° ° ROY EDMONDS St. Louis Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts 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 5éth Sts. 100 East 42nd 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 This Week in... Editorial Our Industry Goes “All Technical Articles Carbide Tools for Shell Work. Radiography Foundry Tool Silvered Glass Floor Lamp Metal Cleaning Novel Packing Table Bolts—Material, Heat Treatment, Physical Properties Micro and Macro Structures Gray Iron Calculation Milling Feeds and New Equipment: Plant Service Apparatus Aluminum Can Brazed Features Assembly Line Washington West Fatigue Cracks Dear Editor News and Markets This Industrial Week News 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 Advertiser Copyright. 1942. by Chilton Company (tae.) 124 131 132 133 135 136 138 140 162 199 x, 4 a j a . | \ | | t | | | | | | y | | J Type SX, combination timer, fully elec- tronic. For spot, seam pulsation weld- ing. Where frequent changes timing are necessary. THE IGNITRON TUBE PIONEERED WESTINGHOUSE Makes Possible Split-Second Timing The Westinghouse development the Ignitron tube has made possible make and break circuits noiselessly with split-second accuracy many 600 times minute without any moving parts. Westinghouse RESISTANCE 38—THE IRON AGE, May 14, 1942 SYNCHRONOUS TIMERS SYNCHRONOUS TIMING Starting and stopping zero point pro- duce even wave form—uniform “heat.” NON-SYNCHRONOUS TIMING Random (non-synchronous) switching may produce this type wave dictable SEPARATE CONT, Where thin pieces metals with critical fusion points are welded, random (nonsynchronous) switching responsible for high rate rejects. Unpredictable transients mean unpredictable heat— burn through, warping, and even cold welds. Westinghouse Synchronous Timers eliminate these transients—they start and stop current always the zero point the current wave, later (when heat control used). result, each weld duplicate the preceding one because its wave form the same. With these Westinghouse Timers, you can mass-pro- duce short-time welds uniform strength and sound- ness. Metallurgical characteristics can controlled (stainless steel will not lose its inless properties) and minimum. There’s Westinghouse Control that will fit your present requirements, whether it’s production seam welding only, combination spot, pulsation, and seam welding. Ask your Westinghouse representative for the facts about this precision electronic control. Westinghouse Electric Mfg. Co., East Pittsburgh, Pa., Dept. 7-N. WELDING CONTROL | MAY 14, 1942 ° ESTABLISHED 1855 Our Industry Goes Out” HORTLY, when the recent orders take effect, every pound steel produced this country together with every pound copper, brass, aluminum other metal will directed the war effort. This the first time modern history that such complete concentration resources has been devoted single purpose. And the fact that the United States, greatest metal producer and consumer all nations, thus “shooting the works” victory illuminating its portrayal the size the job have do. logical and inescapable sequence the diversion materials war purpose the man power the industry the same objective. Materials, man power, machine power, horse power are inex- tricably linked our industry and where one goes, the rest must follow. What will this mean the metal-working industry? What will mean those consumers metal products who cannot claim even remote relationship Mars? will answer the latter first because simpler. Fortunately for consumers, metal products are capable lasting for quite while. They wear out slowly and indeed have usually been discarded long before the termination their natural life. The civilian population cannot exist the food that has previously bought because that has been consumed. But can very well make its present frying pans, typewriters, coat hangers, cuspidors and hairpins for many, many months come, pinch. for the producers steel and other metals and those who convert these materials into metal products, their ways doing business are being changed far more than the nature their products. Some people seem think that automohile production has ceased and that the automotive industry now devoted making planes, tanks and guns. still making lots cars but the people who will drive them are soldiers and not civilians. Steel and Bethlehem and all our other producers this precious metal are still the steel business and will for the duration and long afterwards. And they are still turning out their accustomed product—steel. Directly and indirectly, for the war effort and for the use the men the lines and behind the lines who are executing that effort, there are very few metal products that will not required play their part our program. There will not many “discontinued lines,” aside from novelties and luxury products, one might think. For Mars needs nearly everything. The pinch comes with the producer who small that Mars can- not see him whose voice weak that Mars cannot hear him. The big fellows have already and will have plenty business, but many these little fellows are still serving needs for want war work. Waste tears, friends, the plight the consumer nor the chance survival the large industrial concern. But lend hand the little fellow, now. needs it, and need him expect emerge democracy. — | 7 | 7 q | ° 4 7 4 4 a 7 | | Here Plant Capacity Contracts Subcontracts Will Put These Men and Machines into the Fight Throughout the Middle West are many plants that are available part all the time for additional war work. Inland has asked many these plants with avail- able equipment prepare brief outlines their facilities for war work. Some the outlines are listed below for the purpose helping these manu- Mich. washing and ironing machine mfr. emp. 835 work- ers With complete modern mfg. and ship- ping facilities. Equip. includes punch presses, welders, benders, bead rollers, cold rolled forming machines, dryer ovens, riveters, sheet rollers, roller level- ers, sander dises, slitters, shears, spray booths and complete bonderizing equip. Wis. mfr. small farm equip. and hardware emp. about 125 men per shift, has approx. 20,000 sq. ft. sp. plus 11,000 sq. ft. warehouse. Equip. includes turret and engine lathes, shapers, multiple spindle drill press, many punch and drill presses, external grinders, bulldozers, and wood working equip., blacksmith shop and paint room. Well equipped machine reasonable tolerances, and considerable space for floor and bench assembly. Large Iowa mfr. farm equip. and sheet metal prod- ucts desires more war work. Facilities include 14” and 16” engine lathes and turret lathes; punch presses bulldozers; are welders; sheet metal shears ga. 10’; drill presses 30”; complete tool room for dies and jigs; Bonderizing plant; Electro-gal. plant; spray booths and baking ovens; drafting and engineering depts. Wis. stove and range mfr. with over 50,000 sq. ft. space, emp. 58; has machinery including lathes, shapers, boring mill, presses, brakes, tapping machine, shears, saws, welders, grinders, polishing machines, complete grey iron fdry., core ovens, enameling dept. Completely equipped power house. Are financially dependable with ample and capable management. Wis. appliance mfr. com- pletely equip. for sheet metal fabrication emp. 1,000, has 500,000 sq. ft. excellent shipping facilities. Fabricating equip. includes: 129 punch presses 150 tons). toggle and draw presses, hand folders, box brakes, power drill presses, power and foot shears, circle shear, metal and wood saws, wire cutters, 40—THE IRON AGE, May 14, 1942 facturers make contacts with overloaded “prime” con- tractors and Government agencies. Write, wire, Inland for the names and addresses resistance and electric welders. Mach. shop has auto. screw machines, turret, speed and eng. lathes, mill- ing machines, weaving looms, warp- ing machines. Tool room includes: eng. lathes, milling machines, filing machines, shapers, grinders and planer. Plating equip. for nickel, cad- mium, chrome and copper including polishing and buffing. Have conveyor and stationary ovens, pressure and spraying tanks, booths and dip tanks, complete porcelain enameling equip- ment, also cast iron fdry. Large Iowa agricultural hard- ware and appliance mfr. with 3-acre daylight factory has available punch presses, welders and sheet metal machinery for sub-contracting war work including spot, gun, foot and are weld- ers, power and hand brakes, power and foot shears, punch, drill and hor. presses, bake oven, spraying booths, rip, cut off, and bank saws, and power hack saws, turning and machining lathes, sanding machines, bulldozers, power hammers, eye benders, shapers, milling machines, radial drills, horizontal and tapping ma- chines, speed and polishing grinders, riveting machines, and air compressors. Plant has available facilities for truck and railroad shipment, incorporated yrs., high financial standing. Wis. steel fabricator plate and sheet metal products has ‘available 17,000 sq. ft. production space with equip. including No. verti- punch, high speed power brake, No. shear, No. bending rolls, drill press, and blacksmith forger equip., also air compressor, are welders, flame cutter, acetylene cutting units, and porta- ble saw rig, productive emp. mfg. dump bodies, frames, chassis parts, rock bodies, ete. Mich. furniture mfr. with over 400 emp. desires con- tracts sub-contracts involving sheet metal work. Has modern plant with approx. acres fl. sp. Equip. includes 1—6’, metal shears, 8—10’, 1—6’, 2—5’, 1—3’ power benders, single action punch presses, inclinable power punch presses, deep gap power presses, arch power press, elec. spot welders, belt sand- any the following plants. Even the type plant you need not listed, may pay you get touch with because have and are continuing assemble information additional plants. ers, grinders, drill presses, rivet- ing machines, buffing machine, gas welders, arc welder, tumbler, cut- ting shear, surface grinders, lathes, planers, shapers, milling planer, drill presses, filing mach., press, power hack saws, contour saw, and metal band saw. agricultural mach. and equip. mfr. with 350 emp. working one and one-half shifts, has 96,800 sq. ft. pl. sp. two acres available for exp. Transportation facil- ities from three ry. and six trucking co. Having just comp. Gov. sub-contract work has available equip. including auto. screw machines, bulldozers, hammers, furnaces, forges, forging furnaces, gear hobbers, grinders, key seaters, eng. lathes, speed spin- ning lathes, turret lathes, milling machines, presses (arbor), draw presses, and drill presses, punch presses, metal saws, shapers, rotary shears, bending roll, bench folder, and sheet shear, threading machines, weld- ers, with complete wood working and misc. mach. shop equip. Wis. toy and stamping mfr. with two factory buildings (300,000 sq. ft.) emp. nearly 1,000, has facilities for war contract work includ- ing punch presses (2-ton hydr. No. 3), cadmium and nickel plating equip., are, gas, spot and butt welding, spray booths and dipping equip., also complete wood working dept. Large steel furnace mfr. and fabricator sheet metal ping facilities. Total fact. sp. 175,000 sq. ft. including warehouse and storage, emp. nearly 700. Equip. includes power shears, foot shears, special shears, power press brakes, sheet metal brakes, special folder, punch presses, special forming press, special flanger, initial type rolls, riveters, gang punches, bulldozers, sheet metal notchers, single punches, welding machines, drill presses, special ma- chines and pattern shop equip., melting equipment, molding machines, cleaning room and finishing equip. including buffing lathes, spray booths, and baking oven. | Dearborn Street, Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas City, Cincinnati, New York ° ° ° GAYLORD THOMPSON District Tool Engineer, Vascoloy-Ramet Corp., Houston, Tex. ° ° executive shell manu- ing tool engineer car- bide cut-off tool which had just completed record run 681 shells with one sharpening the tool. The executive founded this unusual perfor- mance compared the cus- tomary production 250 350 sheels per tool grind. “That carbide tool was evidently ‘freak,’” the executive insisted. “It hard believe that ma- terials the machine could have anything with such a.differ- ence production. must something the tool—perhaps the brazing—or, well—something happened during the making that tool that made ‘freak’. Now, what the was there some way check back that?” Confined his own little world manufacturing activities, this executive did not realize that hun- dreds other manufacturers have experienced the same thing with carbide tools. Collectively the gist their ideas would accusing carbide tools having the temper- ament prima donna, the ec- centricities thoroughbred and the changeableness woman’s mind. True, carbide tools have some arbide Tools Shell Work peculiarities about them that cause the staid “old mechanic who has worked with high speed steels all his life cast incredulous glances this “new breed pups” that has upset the old rou- tine procedures. just can’t figure out why the speed increased when the car- bide tool dulled too quickly—nor “why the heck there ain’t clear- ance top the tool for the chips slide off.” just doesn’t make sense! Design has tremendous bear- ing the efficiency steel-cut- ting carbide tools. the design the tool faulty, there will spasmodic performances. the other hand, carbide tool designed according accepted carbide tool procedures may perform decid- edly satisfactory fashion and then suddenly rocket above all heights calculated endurance and thus stamped freak. Now then, this freak performance not exclusive characteristic carbide tools. Other steel cutting ma- terials, too, show considerable variation performances within their range respective capaci- ties. “lucky run” uniform grade material being machined very important factor un- usual tool performances. Shop ex- ecutives are prone overlook this fact and called their at- tention, dismiss such possibilities -as too fantastic—that the odds are too great against such possibilities. Proper carbide tool design prac- tically forces the blame occa- sional freak performances the materials being machined. discussing this matter, first interest. consider carbide cut-off tools and rough turning tools. These tools take about the —Car- bide tipped cut-off tool for 90-mm. shells. THE IRON AGE, May 7 4 | >. | w d 7 ABOVE 2—Ring metal removed the cut-off operation. The wall the rough (A) (B) forging about in. thick. ° RIGHT 3—Too thin shank for cut-off tool leads danger the tool being forced out alinement the setscrews severest punishment any tools used shell production. The tool that made the record mentioned the first paragraph shown Fig. This carbide cut-off tool was operated speed 303 ft. per min. with feed 0.005 in. When the shells were rough and thick scaled, the speed was changed 266 ft. per min. provide more power for the machine operate the tool feed 0.012 in. This latter speed and feed, however, not mended for regular production where shells are fairly smooth and IG. 4—This tool with side cutting-edge angle (SCEA) deg. worked well long the shell forgings kept coming with straight face the base. 42—THE IRON AGE, May 1942 uniform. The feed 0.012 in. was used get the cutting edge the carbide tool through the rough scaled surface and into the steel before any great damage done the cutting edge. Fig. shows the nose-end the shell which the cut-off opera- tion was performed. The wall the rough shell approximately 11/16 in. thick. Until recent months, manufac- turers carbide tools were little leery about recommending carbide cut-off tools—especially for steel. There was too much danger Carbide Line “weave” and overcome this pos- sibility the tools recommended had much width that they did not chatter operation, they would removing too much good material. The size the carbide tip also boosted the cost excessively. definite necessity that the width carbide cut-off tool kept within proportionate range its capacity. other words, the cut-off tool shown Fig. has cutting edge 5/16 in. wide and can cut into material depth approximately in. limited the length the blade from the cutting edge the shoulder the shank. This tool will cut-off solid piece steel with maxi- mum diameter approximately in. steel tubing with wall approximately in. thick. Now then the 5/16 in. wide’ blade were used with tool depth capac- ity in. instead the in. shown Fig. the danger weave would decidedly greater and would put severe bending strain the relatively inelastic carbide tip. The length the carbide tip should not extend be- yond the possible bending point the blade the event its weaving. Blame often placed upon the carbide tip when the cut-off tool Here again, the design might fault. Many tool engineers, their commendable efforts con- serve steel and simplify construc- tion, grasp the idea using thin bar stock equivalent thick- ness the width the carbide cut-off tool they wish make. The trave/ face IG. 5—With draft angle the bases the shells, tools with lead angle SCEA deg. start give trouble. fallacy this thin-shanked cut-off When the operator clamped this tool the turret, the three set screws ate their way into the shank and distorted the alinement the tool. Any mechanic knows what this will the business end the tool when starts work. Ten times out will jam the cut and break the tool and perhaps spoil expensive ma- terial. fact, cut-off tool this type did cause considerable trouble shell work, protective shims not withstanding. The design shown Fig. illustrates how wider shank takes the set screw impres- sions without distorting the aline- ment the tool. any event however, always best use properly hardened shim between the points and shank. This will permit greater degree fine adjustments because there will screw “pockets” pull the tool back into undesir- able position when screws are tightened. Carbide Turning Tools the design steel-cutting carbide turning tool, the side-cut- ting-edge-angle, also lead angle, plays tremely important role the effi- This angle shown deg. Figs. and Future reference this angle will noted SCEA, rather universally under- stood initialed code for side-cut- ting-edge-angle (American Stand- ard 5.13-1939, Terminology and Definitions for Single Point Cut- ting Tools). certain shell manufacturer was having considerable difficulty with steel cutting carbide tools for rough turning shells. When shell manufacturing first started his plant, the shell forgings had straight face the base, Fig. The deg. SCEA the carbide tool was sufficient for this type forging and production went along very nicely with this shell and tool combination. Suddenly things started haywire. Tools started break increasing amounts until was finally necessary get ship- ments more tools via air ex- press from the manufacturer. carbide tool engineer was called in. Referring again Fig note that long the shells had square-faced base, the deg. rough turning tool permitted the Increasing the side cutting angle improves tool performance turning when there large draft angle the base. The tool shown has produced over 500 90-mm. shell turnings be- (A) tween grinds. cut start point back the nose the tool where strong- much desired condition, whether for turning shells any other steel products. Now then, when the carbide tool engineer came the job dis- covered something. Shells were coming into the production line with deg. draft angles the face the bases! And the car- bide tools had only deg. SCEA! HOLD EVERYTHING! Fig. shows how deg. base- face lines with deg. SCEA the carbide tool. This condition wrecker dispositions, pa- tience, and TOOLS. Here steel-cutting carbide tool abused the extent that forced flash-cut its way through in. wall hard oxidations the start the cut. Give this oxida- tion broad front work and will eventually flatten the cut- ting edge attack any steel-cut- ting tool. This scaled surface the shell would dull the cutting edge the tool such extent that portion the carbide tip pushed off before the tool can get beneath the oxidized surface and start whittling away the neg- ative rake carbide tipped lathe tool places pure compressive load detrimental shear load produced the zero back with normal front relief deg. shown steel-cutting carbide tool that has deg. SCEA and considered very popular with shell manufacturers and though this tool does provide for slight “sneaking in” effect shell base with deg. face, still works too fast the start the cut and almost classifies with the plunger type shown Fig. However, this deg. tool “goes town” production shells with bases having deg. less their faces. Where general all-around car- bide tool performance desired— where tool practically prayed for that will meet with all in- consistencies shell forgings— Mister, you have “honey” the tool shown Fig. The deg. SCEA sufficient take care any draft that might put the face the shell base whether this will ever ap- proached exceeded. couple Shear Compressive only Negative rake IRON AGE, May 14, 1942—43 Carbide (B) l. f J e n (A) le (B) IG. 8—Detail carbide turning tool with deg. negative back rake. ‘Note how the angle the tool provides for “easing in” the carbide tool into the rough shell. has tendency flake off the scale before this hard ma- terial has chance any dam- age. This tool gets under the that the balance the cutting edge has clean sweep the machining the unoxidized steel lying underneath. This design tool has produced over 500 90-mm. shells with one sharpening. How- ever, there are other factors that contribute the efficiency the steel-cutting carbide turning tool. The most important these other factors the back rake. Importance Back Rake steel cutting carbide tool with zero back rake, that the cutting edge the tool line with the top the tool shank, which set the centerline the work. With normal front relief clear- ance the tool around deg. (somewhat exaggerated sketch) the forces developed the chip piling against the tool tend break off the overhanging front edge the tool, since all carbides are weakest shear. fact, the cantilever effect this overhang also produces bend- ing moment which resisted the force couple with resulting tension and compressive forces be- ing set parallel the face the tool. The tension force tends pull the carbide tip apart. Now consider Fig. The 5-deg. negative rake angle causes pure compressive action the cutting edge denoted force line And when comes com- 44—THE IRON AGE, May 1942 pression—well, carbide tools love work that way. detailed design the carbide tool with deg. negative back rake shown Fig. This tool SCEA shown the tool Fig. 6B. Here tool that meets all objections. Its sturdy bull-dog tenacity and its reputation for an- nihilating surplus steel makes the ace them all. There is, however, slight objec- tion this carbide tool trated Fig. The tool blocks turret lathes, automatic bar machines chuckers, semi-automatic lathes, may set that tool with in. high shank will automatically bring the point the tool the centerline. Use 5-deg. negative back rake brings the point the tool ap- proximately in. below the cen- terline. This too much for steel-cutting carbide tools. The IG. This stand- ard tool arranged that with deg. back rake, the tip the tool still line with the top the only way that this can corrected raise the tool blocks in. compensate for the deg. negative rake. the other hand, in. could milled planed off the top the shank the back the carbide tip, but this objectionable because involves additional tool costs. much better raise the tool blocks and without the necessity mechan- ical modifications. Recently steel-cutting carbide tools adopted design carbide turning tool which the point the tool line with the height the shank centerline, while still re- taining the desired deg. negative back rake. example the de- sign this tool illustrated Fig. Although this tool will not present completely finished ap- pearance because the carbide tip sticking above the shank the rear, has many points its favor: There the deg. negative back rake without sacrificing cen- ter alinement, there the auto- matic center alinement other tools with definite shank heights, and finally there not much carbide ground when the tool sharpened. When carbide tool mortality as- sumes abnormal proportions the shop, should invite investiga- tion. This turn should resur- rect past performance records over which “post mortems” are held. post mortem doesn’t mean thing solution existing problems. the problem greater production per tool grind, then the tools shown Figs. and should the answer the tool engineer’s dream. \ PHILIP McCAFFERY Chief Metallurgy and Research, General Metals Corp., Oakland, Cal. ° ° ° use radiography for the inspection steel cast- ings well known. Incorpo- ration ments Navy specifications for steel castings and the wide use foundries familiar graphic technique tion. There has been good deal information published this phase radiography, but less has been said about the use radiog- raphy the foundry itself and the effect its use foundry practice. The foundryman who has had experience with radiography in- clined regard its use costly nuisance, avoided possible. also somewhat dubious about the accuracy radiographic inter- pretation. the maximum benefit obtained from radiographic equipment one the first steps consists demonstrating the man the shop that radiograph can very exact picture con- ditions inside casting. Fortunately, this easily done. When shrinkage cavity, other means radiography, the negative asa Foundry Tool Use radiography practical foundry tool for producing sound castings, rather than method detecting defective castings, discussed this article. taken into the shop and the loca- tion the defect marked the outside the casting. Then the metal overlying the chipped machined away until the defect exposed. After few dem- onstrations this kind the men the shop start asking for radio- graphs various jobs they sus- pect may unsound. obvious that radiographs must marked such way that defects found can located the casting accurately. has been the casting which, when first cast, showed cen- terline cated graph Fig. re- designing the cast- ing eliminated defect, Fig. taken the same location Fig. indicates. Section experience the General Metals Corp. that least three marking letters numbers must used for this purpose. These are stamped the casting and lead figures are placed over them that there can covered each film. Casting Practice Changed Radiographic equipment has been use western steel foundry for over year. that time cast- ing practice has been changed numerous castings result radiography. some cases has been necessary change the gating and heading castings, other instances the castings themselves have been redesigned. example the latter case the simple cylindrical casting ft. long and in. diameter, shown Fig. which had been cast many times before and which had always been assumed sound. The out- ward appearance this casting was excellent. Radiographs were taken the position indicated Fig. The films showed hot tears throughout large part the cast- ing due centerline weakness, the side walls being uniform through- THE IRON AGE, May 1942—45 3 if af | 7 | x \ V4 i films | | through the rim pressure door. This door had very heavy rim and relatively thin center portion, design which calls for all the skill and ingenuity foundryman can produced. the radiograph (Fig. shows, the first casting had shrinkage cavity the rim. made from the same pattern after the position the gates and risers had been changed. indicated that the shrinkage cavity had been elim- radiograph inated. this case the use radium showed not only that the hot tear due casting was unsound, but also gave indications the size and position measures could applied with full foundry making pressure work will occasionally find some castings which leak when subjected the pressure test. These can often repaired chipping out the defec- tive area and repairing welding. example this defect shown Fig. The successful remedy this case was redesign the cylinder with taper from top bottom. Radiographs this tapered cyl- inder, taken the same place those the defective casting, showed the redesigned piece sound throughout. typical radio- graph the redesigned cylinder shown Fig. The gating casting and the position the risers are factors which greatly modify the sequence solidification the sections casting and are the utmost im- portance producing sound cast- out the length the cylinder. internal shrinkage cavities and porosity, the principles direc- tional solidification must con- stantly kept mind and any devia- tion from those principles certain examination. Gates and risers which have been believed satisfactory the past have been found many cases this illustrated the radiograph 3—By redesigning, the defect shown Fig. was eliminated this shown Fig. which was taken radiograph corresponding section shows. | Radiographs are found very these cases, both for determining the extent the re- pairs required and for check- ing the effective- ness the re- pair work. typical example piston which was found “weep” under pressure. Since some machine work ready been done before the leak discovered, considerable saving was pos- sible the cast- ing could paired. Although the position the leak could roughly esti- mated visual inspection, neither its exact location nor its extent was known. radium had not been available would have been necessary make costly exploration with torch chipping hammer find and re- move the defect. There also re- mained the possibility that only part the defective area would located and the repairs later found inadequate. The suspected area was, therefore, radiographed, with the result shown Fig. With the exact location and the extent the defect thus determined, repairs were made quickly and successfully. has been found this type work that when defective area has been chipped out, radiograph taken before welding useful determining whether not the chipper has removed the entire de- fect. the radiograph not taken until after the repair completed and the repair then found incomplete, the time spent filling the cavity has been wasted. From the standpoint overall costs, radium, like all good tools, should expected pay for itself. creasing the number castings rejected during machining because unsoundness. There another IG. altering the position the gates and risers the pressure door shown Fig.4, was possible eliminate cavity, this radiograph shows. Fig. cavity pressure door revealed radiography. ij | i 2 | 5 i 3 > way, however, which the foundry savings can made the radium. Checks Gating Practice Approximately half the weight metal poured into mold taken the casting itself. The rest consists the pouring system- gates, sprue and risers. some castings, radiographic examination will show that more risers are needed that the risers should made larger. such cases the yield lowered and sound casting obtained greater expense. the other hand, every shop has castings which carry excessive risers. This usually results from natural tendency put risers every place where there slightest possibility shrinkage developing. There also tendency make risers larger than neces- sary order certain that they will their work effectively. these castings are subjected radiographic examination and control, the necessity for over-riser- ing longer present, and the heading the casting can de- veloped such way that the highest yield consistent with pro- ducing sound castings obtained. should pointed out that not necessary radiograph all castings made from pattern. The usual practice explore thor- oughly the first, pilot casting made. changes are found advis- able the design foundry practice, the casting incorporating the changes radiographed the same manner the first one. Once the molding and pouring procedure has been established, occasional sample will suffice for control pur- poses. Thus far, specifications for gray iron have graphic requirements, nor does 6—The extent and location porous area piston means this radiograph eliminated the need costly exploration with chipping hammer torch. appear that such requirements will incorporated gray iron speci- fications the near future. For this reason there are few gray iron foundries using radium foun- dry tool. Those gray iron foundries Silvered Glass Floor Lamp ACED with shortages metal for floor and other decorative lamps, one manufacturer has de- signed glass base, heavy enough for weight and strength, and coated the underside with silver. The effect was one beauty, with the base having the sparkle mirror. protecting the silver coating with lacquer enamel, the silver, which seen through the glass, retains its brilliance. the lamp base shown the 48—THE IRON AGE, May 1942 accompanying illustration, the hol- lows “dimples” the surface were used for their bead-like dec- which are associated foundries having radium will find that they, too, can use radiography good advantage developing efficient gating and heading prac- tice. Base orative effect, but plane curved surfaces, well other surface designs, may used with varying effects. The silver coating al- most infinitesimal thickness. Simi- larly, tubular and other glass parts are readily coated. The lamp base was developed the Corning Glass Works, Corning, Y., and the coating process, emphasized the American Silver Producers’ Research Project, quite simple and economical. 7 z | | | | MITCHELL Director, Magnus Chemical Co., Garwood, ° chlorinated solvents, the War Production stated that users these materials for metal cleaning will have find substitutes, spite the fact that the work they are doing may carry high priority ratings. This will af- fect manufacturers widely diver- sified lines. Shortages chlorin- ated solvents, already serious, are likely get worse, and consumers are faced with either tion materials cleaning meth- ods carry production. However, unlike other materials that became scarce with the advent the war, the use chlorinated solvents can dispensed with great degree and manufacturers can use other cleaning methods materials. One such metal clean- ing method based emulsifi- able solvent cleaner developed Magnus Chemical Co., and exten- sively used for many years clean- ing automobile and truck motors and chassis. The cleaner sold the form concentrate that mixed the job” with kerosene, safe solvent, any similar low cost mineral oil-based solvent. Mix- solvent 1:8 1:12 parts, the mixture quickly penetrates dirt and grease deposits and loosens them from any metallic surface. does not act primarily dissolve and remove the dirt from the surfaces, but rather takes the “cling” out them and permits removal pressure stream water, leaving physically clean metal surface. The cleaning method using this ° ° Shortages chlorinated solvents bring metal cleaners face face with the problem seeking substitute mate- rials and methods. Discussed here method using emul- sifiable solvents, which are not scarce. emulsifiable solvent cleaner in- volves either spraying dipping the parts the cleaner, followed shortly water cleaning under pressure. According the method saturating the part with the cleaner, the cleaning method known either Emulso-Spray Emulso-Dip. grease, oil and dirt are knocked off the metal and carried away from the work the emulsion produced the action the water the cleaning solution. After such cleaning, the surface ready for any finishing operations except those requiring final cleaning operation produce chemically clean surface, such plating vitreous enameling. the metal surface, there will remain slight film the solvent, but this will not affect finishing operations where physically clean surface sufficient, and will not affect the re- sults subsequent cleaning meth- ods used prepare the surface for plating vitreous enameling. Forty-eighth Series Articles the Technical and Economic Aspects Metal Cleaning and Finishing Emulso- Dip Emulso Spray cleaning can done most cases with both the cleaning solution and the water spray room tempera- ture. Where moderate heating desirable, the solution temperature need never raised much above room rather than hot. While this definite advantage over most cleaning meth- ods, the vital point that Emulso cleaning will remove many dirts that stubbornly resist other clean- ers. Smut steel typical ex- ample, while metal particles adher- ing the interior exterior shell cases the result machin- ing operations are readily attacked this cleaner, whereas vapor de- greasing will not touch them. The penetrating qualities the emulsion cleaner allow loosen the bond between the dirt and the metal surface that cleaning thorough. There are few dirts that the emulsion cleaner will not satis- THE IRON AGE, May 1942—49 ° ° it = f & j Drying parts necessary) Vapor condenser DEGREASER parts here three bath vapor degreaser that has been converted Emulso-Dip cleaner. Baffle plate keep water tap Spray nozzle -Hot water rinse Gas heater Compartment for baskets placed pressure spray rinsed 2—A cleaning unit this design was built firm that had previously used vapor degreasing cleaning machine, and found difficult obtain necessary chemicals. This cleaner was built locally, and was quite inexpensive. Solution under pressure tank 3—This set-up for use emulsifiable solvent cleaner can used for shells and shell cases. Shells are racked over double nozzles the cleaning tank; the inside nozzles spray the shell interior and the concentric nozzles spray the exterior. The same arrangement can used for rinsing the shells. dip may used the cleaning tank desired. 50--THE IRON AGE, May 1942 factorily handle, and may used practically every commercial metal. Since the solution harm- less all metals, there danger tarnishing, spangling, other- wise attacking discoloring the surface metal cleaned this method. From the cost viewpoint, the emulsion cleaning method about per cent cheaper than sol- vent degreasing both because the lower cost cleaning materials and the elimination heat the cleaning operation. The problem many plants that have the past used chlorinated solvents for vapor degreasing oper- ations the shifting over other metal cleaning methods other solvents that will work satisfac- torily existing cleaning machines and equipment. The emulsion clean- ing method can very easily adapted-to mechanical washing ma- chines. There are two basic ways use the emulsion cleaner. One, the spray the work with the cleaning solution, allow soak for few minutes and then follow with the water spray rinse. The other pro- cedure, Emulso-Dip, dip the work into the cleaning solution for minute less, and, after few seconds’ draining, apply the water rinse. Obviously, washing and degreasing machines may adapted one both these methods with very few changes. the other hand, making radical changes some ex- isting vapor degreasing machines, particularly those arranged for dip- ping the part the cleaning sol- vent, possible adapt this method moderate expense, shown Fig. Actually, for many operations the cost setting new dipping spraying facilities and water spray rinsing devices not all insuperable and the economies the process with high production rates and improved cleaning will offset the cost installing the necessary equipment. Where the production rate high and the volume heavy, and where existing machines cannot adapted handle the volume, equipment can designed and built for the two variations the cleaning method. For example, one company designed cleaning unit, shown Fig. based the Emulso-Dip. This unit was built clean parts basket contain- | > 7 er, and the tanks were built locally very low cost. Equipment may likewise de- signed for cleaning one type part exclusively the production rate such part warrants special cleaning machine. Fig. shows shell cleaning unit which the shell racked over double nozzle sprays, one spraying the interior and the other the exterior the shell. The water rinse sprays are spraying the interior and exterior the shell simultaneously. Like- wise, specially adapted machine for cleaning the inside two gun barrels simultaneously shown Fig. designing machine for emul- sion cleaning, parts such shape that will nest readily with other parts that have recesses hard drain require individual rather than bulk handling. Such ma- chine must arranged for stack- ing, racking, container loading parts such fashion that quick, thorough drainage vided and that the water spray and emulsion will reach all surface. This obstacle exceptional, how- ever, since the great majority Gun Sprayers barrel Solution strainer Draming 4—To clean the inside and outside gun barrels, this Emulso-Spray tank may used. work readily accessible both the cleaning solution rinsing sprays. Emulso-Dip and Emulso-Spray methods metal cleaning have been successfully used for over number shops where large shapes cleaned are not readily adapted spray dip machines, special spray booths have been con- structed which the large parts are sprayed with the cleaning solu- tion and then rinsed hosing. Since finishing metal surfaces utility proposition usually, and chemically clean surfaces, while highly essential some instances, are not generally required, Emulso cleaning has proved thoroughly satisfactory, and can used eco- nomically and safely, even under hazardous conditions. The cleaner has its limitations, just any other type cleaning method, since there one complete cleaner ap- plicable all metal cleaning prob- lems. However, there every like- lihood that cleaning operations now based the use scarce chlor- inated solvents can efficiently and economically adapted and handled the emulsifiable method. Novel Packing Table per cent reduction the time required crate air- plane crankshaft has been effected the Ohio Crankshaft Co., through the development novel wrapping table and package. The wooden packing crates for- merly used were heavy, tended splinter, had life expectancy only three trips and were difficult fasten. their place, three- ply corrugated cardboard container nas proved highly successful. This 35x18x8-in. box good for least six trips has solid bottom and top and specially designed cardboard collars hold the shaft place; additional compartments hold the counterweights. Shipping cartons are strapped with 20-gage, steel, placed give support where the shaft weight greatest. speed the strapping special table was devised. Built hold two cases, the outer dimensions the wooden table tops are identical with those the boxes. The cartons, placed end end, are separated well which holds supply the waxed sheets used wrap the shafts. Four channels are sunk the table top and lined with metal prevent the straps from sticking. Through them the steel strapping slipped that will pass quickly around the containers. THE IRON AGE, May 14, 'S F i- e Material, Heat Treatment and Physical Properties concluding the discussion bolt steels, the author describes the heat treatment medium carbon steel bolts, and presents data alloy steel bolts. tails the heat treatment these carbon steel bolts might well consider few the fundamentals involved the practice. produce the maximum physical properties, necessary completely harden the cross-sec- tion the bolt the quenching operation. well involving the rate cooling controlled the quenching medium, this also in- proceeding with de- Taper 1.666 in. per volves the characteristics the steel. The behavior two heats steel, one containing 0.38 per cent carbon, 0.85 per cent manganese, and 0.26 per cent silicon, and the other containing 0.48 per cent car- bon, 0.70 per cent manganese, and 0.27 per cent silicon, both having austenitic grain size ASTM No. after the McQuaid-Ehn test, ABOVE Tapered test specimen. 40 Me Quaid-EHN-2 iG. 8 — Surface (7-32) hardness oil Fracture and water quenched (7-33) 0.38 per cent car- ban steel. The sam- ple was normalized 1650 deg. F., heated 1550 deg. F., held min., and quenched the in- dicated media. Specimen diameter, in. 52—THE IRON AGE, May 1942 JAMESON Metallurgist, International Harvester Co., Chicago comparing Fig. with Fig. 10, there certainly more differ- ence the surface hardness than would expected with 10-point difference. difference accounted for the difference austenitic grain size the 1550 deg. quenching temperature. The 0.48 per cent carbon steel has frac- tured grain size No. 3.0 and the per cent carbon has grain size No. 6.5. This illustrates inadvisability rating the au- stenitic grain size 1700 deg. When steel has coarse grain 1700 deg. necessary also run test 1550 deg. estab- lish facts relating its behavior this lower temperature. Figs. also show that slight difference diameter spells the difference hardening throughout and throughout. This would translate itself into difference tensile strength bolt, and, water quenched, the difference between cracking and not cracking. Fig. shows the appearance quench crack bolt distin- guished from seam, which original wire defect. actual heat treatment the medium carbon bolts, the usual hardening temperature 1550 deg. The most modern equip- ment for hardening includes at- mosphere control prevent scale formation decarburization. This brings very vital con- j | 4 | ° ° } 4 § f | Y | 7 | | | | | | Co., > ul Rockwell hardness Specimen radius,in. sideration, that decarburization. Fig. illustrates decarburization bolt thread. The amount decarburization the wire must controlled within reasonable limits, those usually specified be- ing 0.008 in. maximum totally de- carburized and 0.015 in. maximum total and partial decarburization. Bolts are quenched either oil water with the object bring the complete cross-section Actually, complete cross-section hardness will not always ob- tained. The microstructures completely hardened and under hardened bolt are shown Fig. 14. The tensile specifications fin- ished bolts are usually given minimum for each bolt size and N.C. and N.F. threads actual pounds. The reason for this that engineer will usually in- terested the safe load capacity some particular size bolt with N.C. N.F. thread. One other reason for this that there general agreement the cor- rect area use calculating lb. per sq. in. Metallurgists, how- ever, prefer have values shown lb. per sq. in., they are more familiar with this form. Table III gives the expected minimum ten- sile values for bolt sizes from in. N.C. and N.F. threads and shows the calculated Ib. per sq. in. well the areas based Rockwell hardness Austenitic grain size (7-32) Frac ture ABOVE penetration water quenched, 0.38 per cent carbon steel. The steel was normal- ized 1650 deg. heated 1550 deg. F., held min., and quenched. RIGHT penetration 0.48 per cent carbon steel. was normalized 1650 deg. F., heated 1550 deg. F., held min., and quenched oil. the pitch diameter the thread. These values can obtained tempering from 900 1000 deg. Assuming the bolts are now heat the methods testing employed insure the consumer that has Austenitic size -EHN-2 Specimen diameter, in. 10—Surface hardness oil and water quenched, 0.48 per cent carbon steel. The steel was normalized 1650 deg. F., heated 1550 deg. F., held min. and quenched the indicated media. Austenitic grain size Fracture-3 Specimen in. received satisfactory bolt. The user not primarily interested the exact chemical composition the bolt except know that made from steel containing car- bon within rang