The Iron Age 1942-08-06: Vol 150 Iss 6

AUG 1942 1942 FOR RUSH JOB- When time short and accuracy vital, you need the speed and precision Fairbanks Scales. Exercise your priority get the kind weighing equipment that will serve you best now and the years come. Fairbanks-Morse scale engineers are ready aid you with many ingenious applications. Fairbanks, Morse Co., 600 Michigan Ave., Chicago, Illinois. | X ) ) | unnecessary frills gadgets encumber bombing plane—it streamlined carry every possible pound bomb load. frills gadgets Whiting Victory Crane, either only the equipment needed handle materials most efficiently. OVERHEAD TRAVELING CRANES From docks the clamor for cranes swells urgent crescendo. MUST have more cranes handle the huge volume war materials.” Whiting answers their needs with the Victory simplified, substantial crane designed and built for today’s emer- gency. has every construction needed for its but extras. Whiting Victory Crane you same quiet-running performance ...the same long life and guarantee...and addition earlier deliven Whiting Corporation, 15601 Lathrop Harvey, a ‘ . rw Cc ne, rs 4 7 get deliver AUGUST 1942 VOL. 150, 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 BENEDETTO Resident District Editors Washington Pittsburgh DONALD BROWNE PHAIR Washington Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis BACON Seattle ° ° DIX, Manager Reader Service ° ° Advertising Staff 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 Warren, Box 81, Hartford, Conn. Johnson, Market Research Hayes, Production Manager. Baur, Typography and Layout. ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub lished every Thursday. Subscription North America, South America and Possessions, $8; Foreign, $15 year. Single copy, cents. ° ° Owned and Published CHILTON COMPANY Editorial and Advertising Offices 100 East 42nd St. New York, N. Y. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, GEORGE GRIFFITHS, EVERIT VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, DUFFY CHARLES HEALE Executive Offices Chestnut and Sts. Philadelphia, Pa. U.S.A. Vice-President Vice-President Vice-President This Week in... THE IRON AGE— Editorial Retribution Devoid Technical Articles National Emergency Gear Steels Electronic Rectifiers Applied Machine Training Women for War Work..................... Performance Tipped High Speed Steel Guide for Alloying Elements Used Fusion Welding Cast New Rochling Mill Germany...................... New Equipment: Presses and Pressroom Accessories. Features Assembly Line Washington Fatigue Cracks Dear Editor News and Markets This Industrial News Warehouse Prices Personals and Non-Ferrous Metals Machine Tool Scrap Markets Iron and Steel Scrap Comparison Prices. Finished Steel Products Index Index Copyright. 1942. by Chilton Company | REPLACE PLUG-IN RELAYS NEW WESTINGHOUSE SEQUENCE AND AUTOMATIC WELD TIMERS! New Westinghouse Sequence and Automatic Weld Timers are designed that all operating parts are easily accessible and quickly replaceable. Maintenance, when needed, simplified changeovers timing panels speeded. Valuable production time aluminum and critical alloys saved without any sacrifice precision. Timing circuit relays, for example, are special, tele- phone plug-in type. When it’s necessary change them, they can replaced quickly radio tube! There’s waste motion other maintenance work either. Special swing-out panels make every internal part readily accessible. All wiring, sockets and bases are color coded, that circuits are easy trace. Terminal blocks are the solderless connector type. Automatic Weld Timers control timing weld current and electrode operation where synchronous tim- ing not desired. Sequence Timers are used only time sequence electrode operation where duration weld current adjusted Synchronous Control. Eighteen different NEMA standard types are inter- changeable the one standard cabinet. Write today for Bulletin 3079. Westinghouse Electric Manufacturing Co., East Pittsburgh, Pa., Dept 7-N. CHANGE CONTROLS...IN MINUTES! With one basic installation, you can change control for any different resistance weld operations—in less than three minutes! Entire timing panel released single thumb- screw. All connections main transformer panel are made plug and receptacle. special wiring needed. Westinghouse RESISTANCE 42—THE IRON AGE, August 1942 q 4 j = WELDING THE Devoid Sentimentality AGE AUGUST | ° ° ESTABLISHED 1855 ° Americans are tender-hearted people, but not altogether con- sistent our tenderness. For example, teach our infantrymen the technique bayonet fighting, the lesser part which, perhaps, the operation sticking the bayonet into one’s and the greater part having with the use the gun butt effect indescribable foul. learn how pierce, burn, blow-up, blast and batter our adversaries and having done so, seek out and sort their remains, honor them with military funerals, fire salutes and blow taps over them; photograph the process glorify- ing these implacable enemies and send pictures them with publicity releases all the newspapers. catch saboteurs who come blow our industrial establish- ments, bridges, department stores and water works, and instead shoot- ing them the spot, our delightful antagonists would our boys similar case, convene the Supreme Court leave stone un- turned their defense; thereby extending cordial invitation other saboteurs come over and meet our best people. learn from columnists and from diplomatic officials who have returned from the Far East the degradations heaped upon our unfor- tunate fellow countrymen who have been captured the Japanese. Yet other columnists and writers say that must never descend such levels but our treatment Japanese prisoners give object lesson the application the milk human kindness. Stuff and nonsense. This war; not tug-of-war. war the finish and devil take the hindmost. eye for eye and tooth for tooth; jungle battle the West and the East which our antagonists show mercy and deserve more than one would show toward insane and obsessed leopard men whose pleasure kill and tear innocent victims with their artificial claws. This silly, sanctimonious sentimentality, akin the emotional intoxication that causes some women—and men too—to hover tenderly over convicted murderers and other criminals who have committed re- volting crimes. hope that this same spirit tenderness towards our enemies will not overpublicized that will affect the men and women who are work our industries. For that case, might lead planes that would not fly, guns that would not shoot, and tanks that would not run. | | | | ° ° | | } | | | | | ree by | | } CONSERVE STEEL For Our Fighting Forces Foresighted management now doing everything pos- sible conserve the steel already service, making last that all new steel can into America’s war effort. Preventing corrosive destruction one effective way conserve steel and help fight the war on.the home front. The initial step critically examine all buildings and equipment— bridges, columns, trusses, floors, stairs, roofing, siding, ventilators, ducts, piping, tanks, fences, cranes, machinery, etc.—everything made steel that subject corrosion from dampness, the weather process fumes. SHEETS STRIP TIN PLATE BARS RAILS Wy LO Oy, yyy PLATES TRACK ACCESSORIES Paint manufacturers can offer good advice effective methods cleaning, and primer and finish coats that will protect and conserve steel and about your plant. program preserve steel has valuable secondary advantage, too. Many shades paint reflect light, and better lighting cuts spoilage, speeds production and re- duces the hazards accidents America’s war workers. conservation program more than pays for itself lower maintenance and replacement costs, but more important now, every pound steel that saved boost the war effort. FLOOR PLATE REINFORCING BARS STRUCTURALS PILING ty WS" Wg : ° ° ° DAVIS Chief Metallurgist, Warner Gear Divisio. Borg-Warner Corp., Muncie, Ind. ° ° ° NTIL 1941, the gear industry had available over dif- ferent recognized alloy steels. addition, the manganese the carbon restricted narrow range; the steel could resulphur- ized treated with special de- oxiders such grainal; such modifications were deemed ad- vantageous particular machin- ing heat treating practice could made. There was always steel producer ready and willing com- ply with the customer’s specific re- quirements. Although the Society Automo- tive Engineers steel specifications have been regarded standard for many years throughout industry America, Canada and several for- eign countries, many consumers de- veloped steels suit specific needs. Those General Motors, Ford, International Harvester, and Chrys- dition, the aircraft industry and the Army, Navy, masters’ agencies had specifications applicable ordnance and aircraft materiels. All these have fol- lowed the general pattern SAE standards, yet their minor differ- ences have multiplied many times the number steels actually em- ploved for gears and other The American Iron and Stee! In- stitute, having the means for ascer- taining the relative tonnage all steels delivered from the various steel mills, made thorough com- pilation the different types and National mergency ear Steels Gear manufacturers, faced with ever-increasing shortages alloy steels normally employed such products, were finally faced with problem making serviceable gears the new steels. How they over- came this problem described series two articles, which this the first. amounts purchased and found there were existence several thousand different steel analyses. elimi- nating minor modifications similar steels, the Institute finally reduced these basic alloy steel specifications. These steels either were sold sufficient quantities justify their inclusion were special application manufacturing. The Society Automotive Engi- neers made similar compilation and reduced the number alloy steels from the 1941 SAE Handbook, with these tonnage consumed. But the canvass the automotive and parts makers was, course, much more incomplete, sented less than per cent the alloy steel consumed America. The presentation the new In- stitute specification booklets the public early 1941 was followed immediate attempt impose these standard upon industry overzealous sales agencies. Some warehouses stocked only the Insti- tute listed steels and some instances refused accept orders for SAE steels. This aroused re- sentment among buyers automotive and allied industries and also Army, Navy, and quartermaster departments, where specifications were based SAE steels. Furthermore, there were existence several million blue prints bearing SAE designations for steel. Several abortive efforts were made other specification writing so- cieties alleviate the confusion existing until finally the Office Production Management insisted that the Steel Institute and SAE cooperate and establish similarly numbered specifications based the SAE numerical system. After series meetings be- tween the two societies, differences were adjusted with the final ami- cable result that both now use in- terchangeable numbers except that the Institute carries much longer list. The reason for this that the steel industry, which sponsors the American Iron and Steel Institute, supplies many purchasers not the THE IRON AGE, August 1942—45 cat he 4 a 4 vs he ive rs. \ . | | group, such the ma- chine tool builders, railroads, tric and petroleum industries, etc. Nickel Shortage Alarming tne nickel shortage became gear were alaimed. Any deviation from the nickel bearing steels was regarded with the greatest apprehension be- cause these steels were well estab- lished the gear industries de- pendable types. such SAE specifications 2512, 2515, 3140, 3145, 4320, 4620, 4640, 4815, and 4820. These groups, with the exception the chromium and high manganese steels, repre- sented the commonest gear steels with many years satisfactory operation for transmission and rear axle gears passenger cars, trucks, and buses. Necessity immediately several gear makers substitute chromium-vanadium types, but sooner were few heats delivered and process than became ap- parent that any shifting the because the war was shutting off supplies vanadium. While difficult arrange these changes clean cut chrono- logical order, might stated that the next step, from September December, 1941, was over the chromium-molybdenum steel, 4120. This steel has never been popular the gear in- attending its heat treatment and its lack core ductility. true that had found some favor the agricultural industry service usually less severe and intermittent, but never acquired substantial footing among motor car builders. Several times during the past years has been resurrected, but invariably after testing, was again discarded. late 1940 the chromium-molybdenum steel was proposed SAE specifica- tion, but was rejected the metal- lurgists composing the Iron and Steel Committee this society be- cause its minor application, standardization chromium con- tent, and unfavorable reports comparison with other steels. finally appeared the 1942 SAE list SAE 4119 and the Insti- tute A4119 and A4120. With the additional burden thrown upon chromium, Production Board quickly realized that, unless this alloying element was conserved, there would in- sufficient quantities supply the war program. Early 1942 gear makers found they were denied their three most valuable gear steel TABLE National Emergency CHEMICAL COMPOSITION LIMITS, PER CENT Desig- nation Man- Carbon ganese Max. Max. 8024 0.22/0.28 1.00 0.040 0.040 8233 0.040 0.040 8245 0.42 -30/1.60 0.040 0.040 8339 -30/1.60 0.040 0.040 8442 0.040 0.040 8447 0.040 0.040 8630 0.95 0.040 0.040 8724 0.22 0.28 0.95 0.040 0.040 8749 0.52 75/1 0.040 0.040 8817 0.95 0.040 0.040 0.040 IRON AGE, August 1942 the War alloying elements, namely: Nickel, vanadium, and chromium. was Chro- Vana- Silicon Nickel dium 0.20 0.35 0.10 0.20 0.20 0.35 0.25 0.35 0.20 0.35 0.10 0.20 0.35 0.10 0.20 0.20 0.30 0.20 0.35 0.30 0.40 0.20 0.35 0.30 0.40 0.40 0.60 0.20 0.35 0.40 obvious, tnerefore, that new com- would have de- tainty service. Gears used trucks, buses, and certain army vehicles were under the WPB ban. the still available, manganese and molybdenum were the on.y ones left, and was obvious that any future alloy steels must buiit from these two elements. Some sources manganese were shut the war, and demands, due increased steel production, even- tually caused WPB conserve available supplies. Molybdenum Resources High The United States particularly fortunate having ample supplies molybdenum. this country, over 45,000,000 are produced annually, greatly world supply before the outbreak the war. But, unpredictable are the demands for that even molybdenum may even- tually restricted because the high percentage going into high-speed steels replace tungsten. joint group representing the American Iron and Steel Institute and the Society Automotive En- gineers met Detroit early December, 1941, and steel com- positions, named the NESS steels (National Emergency Steel Speci- were proposed. This name was later shortened steels. order not conflict with any established steel specifications the S.A.E. the Institute, and because was believed that these would not permanent, the first compositions were assigned the type numeral 8000 and four silicon- manganese steels for leaf springs were given the 9200 series designa- tion. The latter are outside the scope gear steels and will not discussed, but the the 8000 series are shown Table These steels were literally pulled out the air and comprise group without any history perform- ance. Hence, the first attitude the gear maker well the steel buying industries general was When finally became apparent, however, that the former types were longer available except for certain very special applications, steel buyers became more receptive and were willing test out these worth. When were made | q | | | | Rockwell Hardness where these steels could bought, was found they did not exist and were unobtainable. However, the WPB soon came the rescue and rulings permitting heats each these steels made and small lots allocated number different plants for testing. Those designated the 8000 series fall into two general groups: The manganese-molybdenums and the chromium-nickel-molybdenums. Those ranging from 8024 8547, consisting present eight steels, comprise the first manganese-molybdenum group. The remaining eight steels, numbered from 8620 8949, are the chromium-nickel-molybdenums, and represent the second group. The inception the chromium-nickel- molybdenum steels was based the theory that diffusion small amounts several alloys might ac- complish much larger quan- tities fewer alloys, and, the same time, take care alloy resid- uals. Three different types are rep- resented the steels, namely: Carburizing grades, semi-harden- ing and full-hardening steels. Very little history available the manganese-molybdenum types Rockwell Hardness except that similar compositions were tried out for gears between 1930 and 1932. that time, the experiences with these steels were not encouraging because the lack uniform hardening properties, gear distortion, and manganese segregation. Steel producers that had been promoting these steels finally discontinued advocating them for gear purposes. Since then, however, grain size came under more definite control, steel making has advanced considerably, and an- nealing and heat treating processes and equipment have improved. possible that this steel. correctly made and properly processed, may eventually prove excellent alter- nate for other alloy types. The higher carbon grades manganese molybdenums never been completely discarded this country and have been em- ployed quite extensively England for agricultural and railroad uses. They are reported excellent for parts that are hardened and tempered. According data sup- plied Climax Molybdenum Co. these steels compare favorably with SAE 4140 and SAE 4340 harden- ability. Two British specifications for Brinell Hardness Number 302 effect the addition 0.20 per cent molybdenum 0.40 per cent carbon steel bar 229 shown these hardness distribution graphs. The chart left shows the hardness distribution SAE 1040 round steel bar, oil quenched from 1525 201 deg. right, hardness distribution charted for fine grain, carbon-molybdenum round steel bar, oil quenched from 1525 deg. manganese-molybdenum steels are follows: Type Type Element Per Cent Per Cent Carbon 0.25 0.40 0.30 0.40 Molybdenum 0.20 0.40 0.40 0.55 Sulphur 0.05 maximum 0.05 maximum Phosphorus 0.05 maximum 0.05 maximum Silicon 0.35 maximum 0.35 maximum The British type corresponds favorably with 8339, but there none the present list that exactly corresponds the British type II, the higher molybdenum specification. nearly can determined this time, the only manganese- molybdenum gears made date are 0.45 per cent carbon. This has replaced such gear steels SAE 1340, SAE 4140, SAE 4640, and SAE 5140, and this same steel has also been used for transmission shafts. None the carburizing 8124, reported yet actual use. matters stand present, the main obstacle the wider adoption the manganese-molybdenums the lack familiarity with their properties and insufficient experi- ence handling gear makers. THE IRON AGE, August 1942—47 and ' 50 en- rve rly ies ble ite | However, early reports investi- gators indicate that possess good depth-hardening prop- erties, they machine satisfactorily all operations, and their pub- lished tensile values compare fav- orably with other alloy types similar carbon content. The chromium-nickel-molyb- denum types are offered at- tempt obtain the enhancing qual- ities these three elements, but using lesser total amount the alloys. low alloy content really improves steel more than would expected and more than gen- erally believed. For example, steel containing 0.5 per cent nickel was listed the SAE specifications until the 1940 revision SAE 2015. This steel was once used ex- tensively for low-priced nickel hardened oil after carburizing, producing file-hard wearing sur- face. Considering the small amount nickel contained, these gears gave excellent record for me- dium and light service. The same carbon steel without would not harden oil. similar improvement hard- enability noted small amounts molybdenum are the steel matrix. The Climax Molyb- denum Co. illustrates this differ- Standard Series Designation TABLE Steel Substitutes for SAE and Grades Possible Steel Alternates Standard AISI SAE Grades { A1340 A1340 1340 1340 4047 2317 2317 2317 2315 4027 8024 8620 2330 2330 2330 2330 4037 8233 8630 2340 2340 2340 2340 4068 8442 8744 2345 2345 2345 4068 8447 8749 3120 3120 3120 A4027 NE8024 8620 A3130 A3130 3130 3130 4037 8233 8630 3135 3135 3135 3135 4063 8339 8739 3140 3140 3140 3140 4068 8442 8744 3150 A3150 3150 4068 8547 8949 5120 5120 5120 4027 8024 6150 6150 6150 4068 8447 8749 48—THE IRON AGE, August 1942 ence the accompanying harden- ability charts, showing the hard- ness SAE 1040 and steel with the same carbon content but with 0.20 per cent molybdenum addi- tion. These charts are shown Fig. Chromium aiso similarly potent. follows, therefore, that minor amounts nickel, chromium, and molybdenum should produce ex- cellent alternate steels. Most gear makers are inclined look with favor these new chro- mium nickel molybdenum which includes three carburizing grades, namely, 8620, 8724, and 8817; and three oil hardening grades, 8744, 8749 and 8949. The SAE and that can replaced the various new steels are shown Table II. rule, 8620 employed alternate for the SAE 4615 grade and similar steels used for gears light and medium duty. The 8724 and 8817 grades are used substitutes for SAE 2515, SAE 4320, and SAE 4815 SAE 4820, the deep hardening types generally used for large gears trucks, buses, and other heavy duty services. Because these steels are com- paratively new, there not much service data base tangible con- clusions upon, although consider- able data available hardenability and tensile values and some dynamometer tests have been made. number research departments leading steel plants and motor car manufacturers, and the International Nickel and Climax Molybdenum Companies are con- ducting extensive tests these steels. committee has been formed under the direction the War Pro- duction Board, known the Re- search Sub-Committee for Tech- nical Advisory Committee (T.A.C.) arrange for the efficient conduc- tion these tests. Tests are in- clude: Tensile, torsional, dynamom- eter, Charpy, and tests not only room temperature but —25, and —65 deg. Other properties investigated are machinability, carburizing and hardening, and grain coarsening temperatures. data will released soon available. doubt when this research completed, some analysis modifica- tions will made and possibly some substitute analyses proposed. Even this early date, there some the brittleness 8724 for gearing and many are recommending replacement new composition known 8720. This new analysis will be: 0.18 0.23 carbon, 0.70 manganese, 0.40 0.60 chro- mium, 0.40 0.60 nickel, 0.25 0.35 molybdenum. The increase the molybdenum assure minimum 0.25. steels will not attempt follow the procedure, too common the past, continually modifying standardized acceptable steels and applying hypothetical numbers suit specific applications, thus creating confusion sarily increasing the number these steels. The purpose the standardization project reduce the number steels minimum well conserve strategic ma- terials. the chromium-nickel-molyb- denum types, three are suitable for oil-hardening gear steels. These are 8744, 8749, and 8949, and they could replace SAE 5140, SAE 4640, SAE 3145, and SAE 3240. However, there record present these substitu- tions having been made, although some firms are experimenting along these lines. Editor’s Note: next issue the author will describe the Amola 4000 series steels, well the equipment used the heat treatment steel gears. Electronic Rectifiers Applied Machine Tools rating plant and its distribution system, one the largest air- craft engine manufacturing plants the Middle West has installed large number individual elec- tronic rectifying units for each the machine tools requiring d.c. power for their functioning. These place the usual d.c. gene- applications include magnetic chucks and variable machine tools. The d.c. power supply units each consist small two-tube elec- tronic rectifier mounted directly the base the machine. Input taken directly from the 440-volt a.c. line which already wired into the main driving motor. The 110-volt d.c. wiring extends only from the rectifier the magnetic chuck other d.c. load. Some the advantages pointed out the Mellaphone Corp., which supplied the equipment, are: (1) Large savings wiring ma- terials and reduction valuable man-hours ordinarily required install d.c. distribution lines. though over 250 miles electrical wire and cables were necessary transmit the a.c. power throughout this plant, practically d.c. wiring was necessary, except internal con- nections the machines. (2) Elimination loss volt- age which occurs long d.c. lines. (3) The individual power supply each machine makes inde- pendent all the rest, far d.c. power concerned. (4) The confusion two dif- throughout the building has been eliminated. (5) electronic contain moving parts, mainte- nance and attention are reduced minimum. The use heavy and external views small Mel- laphone electronic rec- tifier used for supplying netic chuck grinder. Two 6-amp. half wave tubes are shown mounted former. variable speed d.c. motors grinder are powered the electronic rectifier shown, incorporating amp. mercury vapor tubes. duty industrial type mercury vapor tubes minimizes tube replacements and provides high electrical effi- ciency. The availability the equip- ment and speed delivery are also important consideration this large installation. THE IRON AGE, August 1942—49 7 = lard- with with larly ium, hro- eels, 615 | 3 | Fear operating high powered machine tools can overcome preliminary light tools bench work, according the experience small arms plant. ANPOWER marching out industry, but wo- manpower marching in, and industry likes it. The women like it, too, for many are leaving “white collar” jobs, such typing, stenographic and secretarial work for the factory. Only it’s clean slacks and shirtwaists instead greasy overalls. Just they forced the replacement the old-time saloon with the genteel cocktail bar, women are slowly bringing the re- finements and quiet efficiency the office into the more less noisy purlieus the factory. the start, the women are frightened power-driven ma- chines that chew and shred steel high speed. first women must “conditioned” giving them light work where they get ac- quainted with steel first hand filing and other bench work, sensi- tive drill presses, etc. close prox- imity the machines, they soon become used them. Finally, they are put onto one with experi- enced operator. They find that han- dling this monster great power ease personified, that sensi- tive their slightest touch. They learn that the work they can with more delicate than the fine old lace made their grand- mothers. They master their fear and then the machine. They always knew had more sensitive touch than men, and here the pulsing, liv- ing truth it. They realize that they are working closer toler- 50—THE IRON AGE, August 1942 ances than the men—spoiling less work. Pride accomplishment born—good workmanship follows. Then their housekeeping instinct asserts itself. keep their ma- chines clean and Steady production results. The war labor force will ex- panded 15,000,000 persons the end 1942 and 23,000,000 work- ers during the vear following, ac- ° NEALEY cording estimates WPB of- ficials. Millions new workers will required and large portion will women. Looking back World War found that per cent workers war industries were women, while today only per cent are women. this compari- son can taken indicator, tremendous industrial conversion from manpower womanpower has only started. the bomber plant the Ford Motor Co. expected that per cent the assembly line workers will women. The ratio female male operators precision machines increasing right along Curtiss- Wright and other big companies. How individual companies handle this problem? One concern experiencing the benefit the fe- NSPECTION small arms components ideal occupation for wo- man. Even the good looking ones are more patient and painstaking than men this class small work. Var q of- will will cent were per pari- or, rsion ower the cern fe- been prominently identified arms manufacture for many years. Browning working with this concern developed the Brown- ing machine gun, long standard with the Army. Recently, this company, working with the Ord- nance Department the Army, has developed the 37-mm. gun, super-machine gun, based the Browning principle. has two big plants mass production machine guns and the 37-mm. both anti-aircraft and air- craft type. This plant making the 37-mm. guns employs more than 2000 per- ABOVE grinding machine gun components and light cannon now being performed women well-known New England arms factory. RIGHT light inspection work, the sensitive drill press machine best suited for female labor. Use box jigs reduces the precision practically zero. Girls are often faster than men this type work. sons, which per cent are women. With the increasing diver- gence manpower the fighting forces, this company anticipates that the proportion women will shortly raised per cent. This concern welcomes women real contribution efficiency and increased production. has well worked out schedule which the women are first put bench work, then, their aptitude asserts itself, progress from filing the simple drill press, then surface grinders, lathes, profilers, etc., and finally the large auto- matic engine lathes, turret lathes and screw machines. fact they operate practically every type machine. While familiarity may not breed contempt, these machines are real outlet for women’s crea- tive instinct and they push them the limit. This concern ruled out the flowing skirt and sleeves hazard- ous has caused ‘the substitution slacks and sleeveless shirtwaists sweaters. The also, must confined with nets and the wear- ing low heeled shoes consid- ered most important. old- time production man accustomed dirt, sweat and grease profu- sion, the neatness and quiet effi- ciency the new type woman going into industry revelation. Schools for the training fore- men, supervisors, inspectors, cut- ter grinders, are maintained this company both for men and women. Classes are held hr. day, seven days week, and all those attending are paid while they learn. morale builder, this company, which large plants, has athletic associ- ation with leagues baseball, basketball and golf, and has pistol and rifle ciub. ‘The women heartily participate these activities. Tipped High Speed OST machine shops have experienced breakage solid high speed steel tools. This breakage usually curs cutting tools special shape, such are used machine small section inside diameters grooves. The produced when small section high speed steel abuts larger section often cause the tool break off through the small section when the cutting strains are applied. Tools that require sharp corners their construction tools that re- quire bending operation often are source excessive tool breakage also. good example where sharp corners are required are dovetail form tools. Such tools often break off near the in- side corners the dovetail. Offset tools for boring grooving opera- tions frequently require the bend- ing the tool shank and the strains caused bending and sub- sequent hardening are often cause for breakage. Large tools subjected heavy strains also cause much breakage trouble. The breakage solid high speed steel tools eliminated tipping the cutting edge area with high speed steel tip, and using tough alloy steel for the balance the tool. The General Tool Die Corp. producing such tools large quantities the use its new process tipping tools with hard- ened high speed steel tips without affecting the hardness during the brazing operation. This company constantly solving tool breakage problems this method. The suc- cess attained General Tool can best explained means several sketches tools where tool break- age has been overcome. For greater clarity, sketches parts machined are also included. recent example successfully solving serious tool breakage problem the use tipped H.S.S. 52—THE IRON AGE, August 1942 LEO ST. CLAIR President, General Tool Die Orange, tools shown Fig. This tool operation tough alloy steel cylinder. The part machined shown The solid H.S.S. tool used the undercutting opera- tion shown and the tipped tool that replaced the solid The tipped tool was made using per cent cobalt H.S.S. tip 3/32 25/64 in. with The tipped tools have been use for two months with breakage taking place. The tool life the tipped tool averages three times the former solid H.S.S. tool. per cent increase speed also being used over the former tool. This increased tool life and higher speed has been made possible the use the per cent cobalt H.S.S. which has greater “red hardness” than the 18-4-1 H.S.S. formerly used, and also because the two point increase Rockwell hardness the tip over the former solid H.S.S. tool. The user stated that the solid H.S.S. hardened hardness 64-65 Rockwell broke often that had lower the hardness 62-63 order re- duce breakage. The number tools required ABOVE speed steel tool which had tendency break the wavy lines. tool tipped with per cent cobalt H.S.S. shown has been eliminated. RIGHT 2—Grooving the SAE 6150 steel bushing shown caused much breakage the solid H.S.S. tool shown The tipped tool shown using the material, gave almost three times the tool life per grind. Steel Tools Give Improved per month was reduced from 300 solid tools less than tipped tools per month. This resulted saving about $1,500 per month tool costs, along with per cent increase output per day. This user has become enthusiastic about the tipped H.S.S. tools and rapidly increasing his use this type tool because the longer life and the increased cured over his former solid tools. Another solid H.S.S. tool which caused much breakage trouble was used cut 3/32 in. wide in. deep groove SAE 6150 heat- treated steel bushing. tool breakage became severe that the manufacturer attempted several times have milder steel substi- tuted for the 6150 steel, but the user this bushing refused con- sider substitute steel. The manu- Solid H.S.S. steel The process tipping low alloy steel shanks with previously hardened high speed steel blanks was first de- scribed the March issue. this follow-up article, the author cites the superior performance tipped tools whose design solid form ordinarily make them suscep- tible cracking. Longer tool life obtained because higher hardness than ordinarily permissible can employed. 18-4-1 H.S.S. with Rockwell hardness 60-62 while the tipped tool had per cent cobalt H.S.S. tip with hardness The solid tool’s hardness had necessarily low order in- crease toughness the narrow, weak cutting edge area that tool breakage could brought down reasonable limits. Since the tipped tool used tough alloy steel support for the tip, were able increase the hardness the cut- Heat treated 6150 steel ting element considerably and hence hardness 260 increase tool life and cutting speed. The operating data both tools are listed below: facturer dumped his problem our lap and have been successful solving it. Fig. sketch shows the part being machined. The solid H.S.S. tool shown while sketch shows the tipped H.S.S. tool. The solid tool Fig. was made Solid Tipped H.S.S. H.S.S. Speed 100 150 Feed per rev., in.. Pieces per grind Cut time per piece, Production per hr. analysis the above table shows clearly the advantages se- cured substituting the tipped tool for the former solid tool. increase production per cent was secured along with real saving tool cost. total solid tools was required per month. Only eight tipped tools are now needed, resulting sav- ing cost about $130 monthly. Tipped H.S.S. tool interesting contrast pre- THE IRON AGE, August 1942—53 age the mes also ool. her balt red vell ner ted oke the re- red 3” Mig h 3” 32 g* /o° Solid high speed steel Made Hardness 60-6] H.S.S.tipped tool Tip cobalt H.S.S. Tip hardness 3—Another internal recessing job that was hard the solid H.S.S. tool shown The tipped tool shown uses less than per cent the original material. 4—Six-tipped circular form tool used replace solid H.S.S. form tool that frequently broke shown the ragged line. | IG. 5—A considerable saving tool cost has been obta fishtail cutter tipping. 54—THE IRON AGE. August 1942 ined this large sented the amount H.S.S. re- quired for each tool. H.S.S. tool contained cu. in. H.S.S. while the tipped tool re- quires but 1/32 cu. in. H.S.S. contained 216 times much H.S.S. the tipped tool. The internal recessing operation discouraging one with solid H.S.S. tool. recess 0.125 in. wide in. deep necessitated tool with circular clearance both sides the cutting edge. The tool was rather expensive build and difficult harden without causing strains. Sketch Fig. shows the solid H.S.S. tool. Breakage usually took place near the jagged line. These tools cost the user $11.75 lots 50, and tools out broke before doing much work. The tipped tool replacing the solid tool shown sketch Ten these tools were supplied and far none has given trouble. Again sub- stantial increase production being secured due the increase hardness the cutting edge and the higher red hardness the per cent cobalt H.S.S. against the 18-4-2 H.S.S. solid tool. The tipped tool required less than per cent H.S.S. compared the solid tool. The user this tool presented with another tough problem. This has with circular form tool that has part the cutting edge extension in. deep 0.046 in. wide which breaks off too easily. felt sure that circular form tool with six tips would over- come the difficulty. Fig. shows the tool question and our method solving the difficulty. The rea- son planned use six tips that our tough alloy steel support never very far from the actual cutting edge. were sure increase tool life and speed due the fact that the solid circular form tool necessarily had Rockwell hardness 61-62 while planned make our tips 63-64 hard. also were going use per cent cobalt H.S.S. against the 18-4-1 used the solid tool. The tipped tool cost about per cent more than the solid tool this case, but estimated would reduce tool cost much per cent this q | > = Z solid tool ation very solid wide tool both tool and sing solid took line. The tool hese sub- ease and job due the tipped tool eliminat- ing breakage. The tool has now been opera- tion and has come and beyond our expectations. have reduced cutting time about per cent increasing speed per cent. Pieces between grinds showed increase 300 per cent. remarkable saving tool cost has been realized large fishtail cutters shown Fig. Harden- ing strains apparently weaken this type tool and result excess tool breakage. The heavy cutting strains that these tools are sub- iected present real problem and this problem was met the tipped H.S.S. tool. Moreover are able again use harder tip than the former solid H.S.S. and conse- quently tool life has been increased. Another interesting angle that brought out this tool that the plant now the process put- ting new tips the shanks that were originally tipped. This, course, adds the savings already realized. These worn tips are re- moved, new ones put and ground the original o.d. The plant daily overcoming the troublesome breakage dovetail form tools. salvage those form tools that have not broken the dovetail area during their useful life, and also salvage those where the dovetail broke initial use. With the tipped tool, the dovetail milled the tough alloy steel shank and hence breakage through this area non-existent. Fig. the construction the tipped H.S.S. dovetail use this construction when are called upon furnish new dovetail form tools. have the H.S.S. plate used for the cutting edge hardened 64-65 Rockwell without any fear dovetail form tool usually two three points softer than this. Hence the tipped H.S.S. form tool this will give considerably longer tool life. recent application has resulted breakage dovetail form tools eliminated brazing H.S.S. plate low alloy shank which the sharp dovetail cut. 2 7—Tipped planer tool used make deep recess not only saves scarce material but also reduces costly breakage. fine increase tool life and real reduction costly This tool planer tool used make deep recess cast iron part. was formerly made out solid piece 18-4-1 H.S.S., in. long, in. wide and in. deep. Fig. shows the tool tipped with per cent cobalt H.S.S. tip in. Here are comparative data: Solid per cent Cobalt Tool Tip Hardness, Rockwell C.... 60-62 64-65 Quantity other words, the solid tool uses 152 times more critical mate- rial than the tipped tool. addi- tion, the breakage difficulty has been solved. all cases tipping with hard- ened H.S.S. tips, the use valu- able H.S.S. drastically reduced. Apart from this saving vital cut- ting tool material, many tools are far superior tipped tool compared solid tool from con- struction standpoint. The much greater strength the tipped tool definitely entitles serious con- sideration whenever tool breakage pronounced with the solid tool. Also the fact that can usually have tip H.S.S. somewhat harder than the corresponding solid tool entitles the tipped tool seri- ous consideration from the tool life standpoint and the consequent tool cost reduction that ensues. This new tipping definitely points new design thoughts for many types troublesome tools. THE IRON AGE, August 1942—55 ° ° >r | the ired ited orm too OWS hod ort life the rily our ilso ent 4 1 ° ° ° ped ore but his interesting guide the relative influence certain alloying elements steel, originally prepared Carnegie- Illinois Steel Corp. and released the American Iron and Steel Insti- tute, affords readily available form information for basing the use certain elements combina- tions elements, the lowest possible proportions, suitable for particular requirements. The ele- ments covered this guide in- clude: Carbon, manganese, phos- phorus, sulphur, silicon, chromium, nickel, molybdenum, vanadium, and copper the ranges listed the When the elements exceed the limits shown, the guide not gen- erally applicable, the presence some elements greater quanti- ties tends impart reverse quite different effect. With the exception the spe- cial, stainless, tool steel grades, the guide covers the major portion steel production and consump- tion. When using the guide, how- ever, must assumed that the steel will given the proper heat treatment and processing cordance with the best practice for the type involved. Unless specifical- noted the guide, ratings are based upon the use the maximum Guide Alloying percentage shown for each element. Two columns are shown for carbon, covering ranges from 0.10 0.30 per cent and 0.30 0.85 per cent. Ratings relating welding, cor- rosion, and deep drawing proper- ties are based the carbon range 0.0 0.30 per cent instead 0.10 0.30 per cent. Numbers indicate the relative effect the element upon proper- ties the steel its response certain processing operations. These numerical ratings are shown the following key. Suffix letters the tables indi- cate the characteristic influence the added element. The straight-line cated the letter indicates that small quantities are most effec- tive; indicates that amounts are necessary for great influence the alloying element; and where some reaches maximum inter- mediate point and then decreases intensity more the element added, the letter used in- dicate that intermediate amounts are most effective obtaining the desired effect. Thus, while not possible determine the exact limits the elements needed achieve desired end, the suffix let- ter indicates large, small, inter- Table Key Numerical Ratings Used the Tables MINUS PERFECT PLUS PERFECT Slight unfavorable effect Mild unfavorable effect Moderate strong unfavorable effect Strong favorable effect Moderate strong favorable effect Moderate favorable effect Mild favorable effect 56—THE IRON AGE, August 1942 mediate amounts any element are most the number it- self indicating the degree favor- able unfavorable effect. For example, small amounts chromium are very effective en- hancing hardenability, the suf- fix letter indicates this predomi- nant characteristic. the case carbon, the function abrasion straight line function, the suffix used. Large amounts nickel are required develop maximum sistance, while small quantities are relatively ineffective, which estab- lishes the suffix the tables. the case manganese, maximum effects are obtained the property ductility hot-rolled condition the use intermediate amounts, consequently the use the suffix. When using the tables basis for making comparisons, must remembered that the merit ratings presented have been developed consideration the effect various elements upon plain carbon steel, such 1015, 1020, 1030, with minimum 0.10 per cent carbon and 0.25 per cent manganese except the case flat-rolled steels. The composition built the use single alloying element listed, that the effect single alloying element low me- dium carbon base composition can studied. The tables have been developed broad terms and are primarily intended outline trends, and should considered source information that will useful reasonable guide the selection, conservation, nomical utilization alloying ele- ments. The accompanying tables sum- marize the ratings developed in- dicate the effect various elements upon the properties steel and its response operations. while important, has been omitted much depends upon the effect the mechanical design and sur- face character. table II, the items forging, annealing, ma- chining, hardenability, distortion, toughness, and wear are involved. table III, abrasion, strength, toughness, cold fabrication, and welding are considered. either case the tables serve illustrate the many factors which add | | — | | | | Elements Use detract from the properties desired the performance required when selecting steel type or.composition for any particular field use. Tables and III serve examples how table may set for practically any application. While they not give the exact combina- tion for best performance under all shop conditions, they will guide the use choosing the most promising elements and will indicate whether Table Steel small large quantities are re- quired effect property re- sponse. They also indicate clearly what sacrifices must made one direction obtain desirable prop- erties sought another direction. Full Rating Number and Suffix Letter Giving the Relative Effect Each Element Several Properties Conditions Steel ABRASION TANCE FABRICATION Deep drawing, break ing MACHINABILITY QUENCH CRACKS, SUSCEPTIBILITY Water STRENGTH TOUGHNESS Heat treated 300 Fully hardened, 300 400 deg. draw Fully hardened, 400 600 deg. Low temp.; heat treated 300 Low temp.; heat treated 400 Lew temp.; fully hardened, 300 400 WEAR RESISTANCE Fully hardened, 300 400 deg. WELDING Ruptures, preheating post heating TABLE Molyb- PerCent PerCent Per Cent Per Cent | | | | Sum all Favorable and Unfavorable Merit Rating Values for Each Element, Including all Properties Responses Machinability, annealed pearlite Wear, fully Totals, minus... Abrasion Toughness, rolled Fabrication, bending Totals, plus Totals, minus... x—probably negative positive TABLE Involved Hypothetical Set Conditions +18 +16 +13 — THE IRON AGE, August 1942—57 — nent it- vor- en- re- tab- num erty tion asis ings ious tha cept use ngle me- can are nds, the ele- um- ents its sing nce, tted Tect sur- the ma- ‘ion, ved. gth, and ther rate using cast iron instead bronze rod, particularly in- teresting today because the The fusion process also more sat- isfactory from the color standpoint temperatures such those encoun- tered welding damaged stove parts. Because few operators have any experience this metal the fusion process will necessary train them its general principles and point out the difficulties they may encounter. Successful gas welding cast iron demands the ability identify the type iron the part welded that may properly heated and cooled maintain those properties after welding. Thus the heat treatment used producing malleable cast iron precludes the possibility fusion welding, but the white, gray and chilled gray irons can successfully welded this process. welding cast iron, Welding Characteristics White Cast Iron must heated all over temperature from 600 1300 deg. F., depend- ing upon the size and shape the and the location the break. the weld located that there freedom for expan- sion and contraction, the lower pre- heating temperature will usually sufficient; otherwise, higher tem- 58—THE IRON AGE, August 1942 peratures must used. Care must taken not overheat when pre- heating the higher range, the parts may sag warp. welding rod and flux made specifically for welding cast iron should used. Oxweld No. cas