The Iron Age 1942-11-05: Vol 150 Iss 19

H NOVEMBER 1942 Must Build Big National Serap Pile for World-Wide Victories ag tis é uy composition. The test design; our Alloy 502, ments. contains “and (please note) 18.5 chromium, and been making for thirty years. THE IRON published every Thursday the ‘CHILTON CO. Philadelphia under act March 1879. vearly North uniform jobs, you should investigate wrought. Tell your problem—we think can help. Hoskins Manu- facturing Co., Detroit, Michigan. Entered second class matter November 1932, the Post Office America and South America. Foreign $15. Vol. 150, No. 19. =" oT —~ ! PRODUCTS FIXTURES SPARK PLUG ELECTRODE WIRE SPECIAL ALLOYS NICKEL PROTECTION TUBES NOVEMBER 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 Art Editor, WINTERS Editorial Assistants Resident District Editors Washington Pittsburgh Washington Chicago Cleveland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON Toronto, Ontario BACON Seattle ROY EDMONDS St. Louis ° ° A. H DIX, Manager Reader Service ° ° Advertising Staff Emerson Findle 621 Union Bldg., Cleveland Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave.. Los Angeles, Cal. Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit East 42nd New York Fitzgerald 428 Park Bldg., Pittsburgh Warren, Box 81, Hartford, Conn. O. L. Johnson, Market Research Mar. Hayes, Production Manager. Baur, Typography and Layout. ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers the Industrial Arts Index. Pub- lished every Thursday. Subscription Price North America, South America and Possessions, Foreign, year. Single copy, cents. ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. 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 V. DUFFY CHARLES HEALE This Week in... Editorial The Spotlight Salesman. Technical Articles Acid and Basic Bessemer Babbitt—Lead-Base for Cementing High Speed Steel Tips Bonding Low Tin Bearings Iron and Automatic Time Temperature Control Heat Treating Magnetic Non-Ferrous Scrap... New Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Coming Personals and Obituaries Non-Ferrous Metals Machine Tool Activity Scrap Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices Warehouse Prices Index Advertisers Copyright, 1942, by Chilton Company (Inc.) 105 151 153 154 156 158 159 160 164 243 U RYERSON Founded 1842 Completes One Hundred Years Steel-Service One hundred years ago, bleak October day, Joseph Ryerson set out from Philadelphia for the West. November 1842, after nine days’ travel train, stagecoach and lake steamer, arrived Chicago, small town about 6,000 and set his little iron store—the first west Pittsburgh—and started business which was destined grow the largest steel ware- house organization the world. Through century peace and war— good times and bad—Ryerson has proved prompt, reliable source for steel dependable quality. From the pioneer establishment 1842, has sprung network ten JOSEPH FOR great steel-service plants, strategi- cally located serve the principal industrial areas. Today the Ryerson organization the thick the war production effort. Emergency calls are coming for steel open production bottle necks and maintain and repair over-worked plants and equipment. The skill which cen- tury experience has taught now under constant pressure make the best use available stocks. With this background service America, and looking forward its second centennial, the Ryerson Organization pledges every re- source until this war won. RYERSON SON, INC. Chicago Milwaukee St. Cincinnati Detroit Cleveland Buffalo Boston Philadelphia Jersey City -40—THE IRON AGE, November 1942 THE RON AGE NOVEMBER 1942 ° ESTABLISHED 1855 The Spotlight Salesmen OME people have said that selling—and salesmen—are out for the duration. That orders, henceforth, will given and not taken. That this sellers’ market, you might well put the sales ship drydock, pull the oars and let down the anchor. have never believed this theory assumption. believe that build business, run successfully and keep going, you must depend heavily upon those enthusiastic and extraverts who fall the category salesmen. Most us, industry and business, are occupied too much with looking any looking out. But not with salesmen. does not matter what kind product real salesman has sell, long good one. And, sobeit this product available him sell, most products today are not. This lack products sell has made some people Washington and elsewhere somewhat skeptical the value selling. Therefore, most refreshing note find that what probably the most critical situation that America faces today, the United States Government, through the War Production Board, has turned the selling profession for imme- diate aid solving serious problem. This problem the collection six seven million tons dormant industrial scrap during the latter months 1942 and the months 1943. The salesmen America are now being recruited for Uncle Service, for service important, not more so, than the service those who gallantly fought Bataan who are now gallantly fighting Guadalcanal. Make mistake about it, are now the defensive. Our retreats and defeats have been glorious but glory does not win war. What wins war steel. The Axis powers have the edge preparation; years against little more than one. They have the edge blind fanaticism. They have the edge military experience. But have the edge them steel production, provided can keep our steel mills going. And this depends entirely upon our ability unearth and put use our dormant scrap. the salesmen America are being recruited for this great task. And will indeed both challenge and test the social value salesmanship. Because convenient handle for this drive, the National Fed- eration Sales Executives has been made the nucleus this action, together with the steel industry salesmen and the steel warehouse sales- men America. But this exclusive party. you are salesman who does not happen affiliated with any these organizations, but who wants his part helping win this war, ask that you write that can put you touch with real opportunity render substantial ser- vice your country. | | | | | | | | | | | ° ° | | | | | | | | | | = | WARNING! The public and industry probably not realize how close many steel mills came last month closing down portion their productive capacity due the lack scrap. fact, Inland actually was forced shut down two furnaces for time. drastic curtailment America’s steel production, because the lack scrap, would national calamity. Today, scrap coming somewhat faster than are using it, but despair that will build backlog sufficiently large provide for all the winter months, when very little scrap moves. must build large scrap piles during these fall months carry through until April, are certain have serious breakdown steel production. Anything that possibly can done give everyone better understanding this critical situation will service our country. INLAND STEEL CO. 42—THE IRON AGE, November 1942 ° CHESTERS Central Research Department, United Steel Companies, Ltd., Stocksbridge, England two features the bes- semer process that cannot fail strike the refractories en- gineer are the extremely rapid rate wear the bottom compared with that experienced the open hearth furnace, and the enormous potential output relation the size the installation. Thus medium sized converter can turn tons iron into steel about min., Whereas 80-ton open hearth furnace often takes hr. achieve similar object. shown Table the relative out- puts per square foot hearth area will seen later, the rapid production rate more than offsets the rapid wear the refractories, which cost per ton steel about 20c. compared with nearer for the open hearth process. For acid work, most the con- verters have capacity about tons, though 10-ton converters are also used. For the basic process, tons may again considered the standard size, but Germany converters 40-ton capacity and over are also employed. Given two acid converters 25-ton capacity working full out, stated that plant refractories, that have ap- peared IRON are: “All-Basic Open Hearth Furnaces,” and 22, 1940. “Steel Plant Refractories,” Feb. and 13, “Basic Open Hearth Above Sill Plate Level,” May and 29, 1941. “Electric Steel Plant Refractories,” March and 12. 1942. “Acid Open-Hearth Refractories,” May and June 1942. “Soaking Pit and Reheating Furnace Refractories,” July and 23, 1942. Acid and Basic Bessemer The author continues his series articles steel plant refractories with discussion two parts, which this the first, materials and construction bessemer converter linings and bottoms. Here describes stone, fireclay, and cement for bessemer use and ouflines re- spective advantages acid and basic refractories. output over 20,009 tons sceel week can obtained. (Figs. and 3.) Other factors are, however, more importance than production rates and refractories costs; for example, the quality the prod- uct, the availability suitable grades hot metal and the general economics the problem af- fected such questions the rel- ative prices pig iron and scrap. Hence, spite these two big ad- vantages only small proportion the world’s steel made the bessemer process. America, the acid bessemer process used, Germany the basic bessemer (more correctly known the Thomas process), while Great Britain both acid and basic processes are employed. both processes, the molten iron from the blast furnaces comes, via mixer, the bessemer con- verters and the amount scrap used small. generally virgin scrap and introduced toward the end the blow the acid process when serves adjust the temperature the metal. the basic process, thrown soon after the blow commences. quite possible that both the acid and basic bessemer process may come back more into the pic- ture the not too distant future, hearth duplex process designed get large outputs for relatively small capital and operating costs. Hence, although the present output only small proportion the whole, study bessemer refrac- tories may general interest. Mixers rare that iron from the blast furnace poured directly into bessemer converters. The nor- mal procedure for pass via large cylindrical mixers which act reservoirs (Figs. and 6). The function these mixers maintain steady supply hot metal for the bessemer, taking the fluctuations the supply from the blast furnace, and give iron more consistent analysis, and hence more standard opera- tion the bessemer process. The capacity the varies greatly, being small 250 tons and large 1400 tons. Thus one acid bessemer plant with po- tential capacity 40,000 tons week, has two 1300-ton mixers, while another with output about 5000 tons week has only one 400-ton mixer. The lining the mixer varies with the process, being generally silica brick for the acid bes- semer, and magnesite brick for the THE IRON AGE, November 1942—43 ° bessemer shop showing three 25-ton converters. 2—Twenty-five ton-acid bessemer converter blowing. 44—THE IRON AGE, November 1942 from the blast furnace passes into the converters via ABOVE large cylindrical mixers, such the one shown left foreground. 3—Twenty-five ton acid bessemer converter pouring into ladle. THE IRON AGE, November 1942—45 basic bessemer. The sents highly specialized problem. The dimensions the mixer are great, and since there are often facilities for additional heating the metal, good insulation most important. Where silica brick used, soft fired quality preferred, presum- the mixer, shrinkage often considerable and may cause premature failure due blocks be- coming loose and out. Where magnesite brick are backed directly with insulating brick, the high conductivity the magnesite (25 B.t.u.) compared with that the insulating brick B.t.u.) re- a 5—Acid bessemer mixer 400-ton capacity. These mixers act also reservoirs. ably due the reduced risk thermal spalling and joints associated with after-expan- sion. Most mixers are lined with blocks made from Austrian magnesite and essential for these adequately fired, re- duce minimum the shrinkage which occurs use. Below the metal level little trouble occurs but the slag level, which varies con- siderably with the amount metal 46—THE IRON AGE, November 194? sults interface temperature only 125 deg. below that the working face. Hence al- though the operating temperatures are comparatively low (2100 2370 deg. F.) slag and even metal may penetrate deeply into the blocks. good deal research present hand this impor- tant subject, but any discussion the conclusions reached date would premature. Both the acid and basic bessemer converter can divided into two main sections—the vessel lining, and the bottom, plug, sometimes called. The lift the vessel lining considerably great- than that the plug, and since the latter detachable, full use can made the life the vessel lining. Vessel Linings The vessels most the Amer- ican converters are lined with sandstone. some plants quite good results are obtained with “firestone,” but the best results appear given special micaceous schist which can readily cut into rectangular blocks because its laminated structure. British acid convert- ers (Fig. lining generally soft fired silica brick. sur- prising that furnaces which oper- ate such high temperatures can safely lined with either raw TABLE Acid Fixed Open Bessemer Hearth Furnace Converter (Cold Pig) Capacity ton ton Conversion time min. hr. Hearth area sq. ft. 350 sq. ft. Production rate: Long tons per sq. ft. hearth per 1.40 0.02 Lb. per sq. ft. hearth area per hr. 2800 42.5 sandstone brick containing sub- stantial quantities raw quartz. Conversion this quartz cristo- balite must take place, least the surface layers, and considerable the cylindrical shape the con- verter body that makes possible such expansion without shape serious spalling. some plants the lining coated before ganister, but others the starting new converter lining with unprotected silica brick standard practice even though these may have specific gravity high 2.52. According one writer who has studied samples American micaceous schist, the typical mate- rial contains about per cent silica, per cent alumina and per cent iron oxide, while Burr and Rayner state that the so- called fire-stones contain cent silica and per cent per cent consisting iron oxide, ta » tye ' uae Fig. through 400-ton acid bessemer mixer. lime and magnesia. The porosity fire stone given per cent with apparent specific gravity 2.14. The melting point 3000 deg. and the cold crushing strength from 8000 10,000 per in. heating 2600 deg. per cent linear expansion The life such lining about 10,000 tons steel (400 blows). This corresponds re- fractories cost for the vessel lining about 10c. per ton. The basic bessemer converter vessel usually similar shape the acid converter vessel, but some plants improved results are said obtained with converters oval section. The lining mate- rial consists tarred basic (dolo- mite high tempera- ture) and this may the form blocks monolithic ramming (Fig. 8). Where blocks are em- ployed the procedure preparing the basic similar that de- scribed later section dealing with the bottoms. Large hydraulic presses giving molding pressure about 5000 per sq. in. are used. The blocks may installed immediately after molding pre- fired like the basic tom. Where lining rammed converter, consider- able attention must paid the tar content which appears critical optimum results are obtained, and which should varied slightly take care the different conditions prevailing different points the vessel lining. The amount tar used varies between and per cent. The im- portance using the optimum tar stressed, this amount, together with the correct firing technique, will affect major extent the useful life the lining. The tar content and burning-in practice both should carefully controlled and only varied terms each other. The lining broken for ser- vice charging with hot coke, and subsequently lime and iron, and blowing until the iron converted into slag the following approx- imate composition Per cent FeO 30.0 20.0 25.0 MgO 15.0 6.0 4.0 the conclusion firing the converter, the lining coated with slag and condition receive the molten charge. 7—Sections through and 25-ton acid bessemer converters, showing construction bottom and vessel lining. Thickness ramming between tuyeres Width vents Channels Blowing Holes each tuyere dia line 8-6 Tuyeres Blowing Holes each tuyere THE IRON AGE, November gear Little appears have been pub- lished the causes destruction converter linings but prob- able that abrasion hot particles metal and slag plays impor- tant part. is, however, recog- nized that the iron analysis, par- ticularly the silicon content has marked effect the life lin- ing. The wear tends greatest region about one-third the distance between the bottom and the converter mouth where the lin- ing tends out, and also the nose. Generally speaking, the life lining four times that the bottom, about 160 200 blows. This only about half that obtained with acid con- verter lining. Editor’s Note: Next week the author concludes this investigation with dis- cussion materials and acid and basic bessemer bottoms. IS. 8—Section through 25- ton basic besse- mer converter. layer removed and with Forced Convection Heating Speeds Heat Treating ERTAIN uted new forced convec- tion type furnace developed the Lindberg Engineering Co., Chicago, provide the heat-treater with speedier processing forgings, castings and other parts which must normalized, hardened, tem- other heating operations. The work range this furnace, known the Super Cyclone, ex- tremely usable the forced con- vection heat obtainable 1750 deg. and all work going into the furnace handled fix- tures work baskets. The high heat limit permits broad scope products treated and handling the work reduced mini- mum holding the same fixture throughout all heat treating operations. example this cited the heat treating gun forgings (Fig. 48—THE IRON AGE, November 1942 where the forgings were loaded into fixture, normalized, permitted air cool the fixture, returned the furnace for reheating, oil quenched and again returned the furnace for the draw, The advantages the forced con- vection heating, which forced high velocity fan, are the elim- ination radiation the work from source hotter than the de- sired work temperature and also the elimination one-sided heat- ing which may cause strain dis- tortion. result uniform heating and spaced loading straightening reduced materially heat treated parts. many instances straightening what- ever required and most other cases the straightening slight that can accomplished speed- ily and with minimum chance injuring highly hardened products. Brick ° ° HOYT LEVY Vice-President, United American Metals Corp., Brooklyn ° ° metal this article not necessarily technical. rather general nature im- press upon its users the importance having more than surface knowledge the subject and designate the rightful place bab- bitt metal the scheme war- time endeavor. Many excellent articles sleeve bearings have appeared the IRON AGE and other publications, but few articles have been written the subject babbitt metal which lines the bearings and upon which the success failure bearing may depend. Since the Japs slammed down the door the tin cellar, this country has gone into dither the hun- dreds things which daily do- ings had taken for granted and which had never thought attaching any importance. Not the discussion babbitt least important the things fected the lack tin babbitt metal. And the pity that most who should have known something about the babbitt metal that essential wag- ing war, know little about newly married bride knows about baking biscuits. The existing tin situation not unlike that which was experienced during the World War, differing the present Global War only that much more acute. But now, dozens with little knowledge bearings, rushed the rescue with formulas for tinless babbitt. And now, most them were only nuisance value, creating much confusion, although few them did have the germ promise Babbitt—Lead-Base for Tin-Base but unfortunately were not fully developed for lack encourage- ment. Though the shortage tin grim reality, the babbitt situation not nearly serious users generally believe have been led believe. With many users, high tin-base babbitt had be- come fetish. The mere mention lead-base babbitt their par- ticular machine would bring im- mediate dismissal the idea. Yet there are thousands bearings machines which had never been lined with any but high tin-base babbitt and which would have func- tioned well, and possibly better, the credit the War Production Board that they had become cogni- zant this fact, evidenced the regulation which limits the tin content babbitt metal maxi- mum per cent, except when re- quired the Army, Navy, Mari- time Commission for implements war. Ed. Note: Grueling trials new lead alloys for bearings are being conducted the Cooper-Bessemer Corp. plant, one the country’s leading producers diesel engines, gas engines and air compressors. According Ralph Boyer, chief engineer, alloys with lead the base metal have been put into bearings the diesel engines and air compressors, and from all indications they are doing very well. However, about year testing will required prove conclusively that lead adequate substitute. The company points out that has been forced turn lead base metal the place tin, but that preliminary indica- tions are that lead will produce better bearings than have ever been produced before. Next the doctor, among pro- fessional men, the writer’s deepest respect for the engineer. The writer marvels his ingenuity and admires the engineer’s blue-prints and the ease with which reads them. But when the engineer dis- cusses babbitt, close the prod- uct his skill, the writer wonders his lack knowledge which not easy condone. Many engi- neers with whom the writer has come contact, seem judge babbitt only its Brinell hardness —an uncertain property babbitt and subordinate importance even when taken relation with other factors. Some determine the capa- bility babbitt only the height its curves the plots its tests for compressive and tensile strengths, disregarding the fact that strength babbitt fac- tor only certain point and that any strength beyond that point superfluous and obtained the sacrifice some other important factor. There more sense having babbitt with compressive and tensile strength beyond the limits its duty plus the accepted margin safety, than there wearing woolen underwear midsummer day because wool warmer than linen lisle. The shelves the Patent Office Washington are weighted down with patents babbitt metal formulas which most the claims stress chiefly the great strength the resulting alloy. With few exceptions, alloys made the formulas described the patent papers are too brittle withstand any kind shock, too high coefficient friction run cool under any kind lubrication. There much more babbitt than high points Brinell, com- pression and tensile strength. babbitt capable resisting wear THE IRON AGE, November 1942—49 need not necessarily deed, Isaac Babbitt’s basic idea was metal which would not heat the shaft friction. might have tried alloy lead with possibly little tin and antimony added. Such alloy would have proven satisfactory for the machinery his day. But Isaac Babbitt was silversmith and also worked pew- ter. that was the natural thing for him make his first test with the material hand. And curiously, all the years since his invention the bearing box, despite the tremendous progress made ma- chinery every kind, alloy for lining bearing operating under heavy load, great shock high speed, has since been found equal Isaac Babbitt’s pewter, the formula which was approximately per cent tin, per cent antimony and per cent copper. The reason for the success Babbitt’s original formula was due the fact that the antimony com- bining with the tin, formed needle- like crystals which intertwined, not unlike tangled shrubbery, forming cushion take the shock. The copper, combining with the tin, formed cubical crystals which, en- meshed the tangle tin-anti- mony needles, furnished strength carry the load. Thus, the result ideal combination for babbitt lining that will carry heavy load and absorb the shock forcible impact. But like the chef’s recipe which the cooks try improve upon, Bab- bitt’s original alloy been changed up, down and crosswise and with almost every known element added, singly and multiples. One the favorite additions make stronger, which comes the fore every often, nickel. Yet nickel, although adding useless strength, detrimental the alloy for the reason that breaks the tin- antimony needles and destroys one the basic factors babbitt. Another babbitt which pops such the present and which has considerable merit, al- loying pure lead with one more the alkali earths very small volume. These alloys are surpris- ingly tough and strong and have the further advantage very low coefficient friction. But re- quires the practice greater skill and more exacting care when re- melting these babbitts for lining the shells, than given the general run factory mechanics, which ex- plains why this class babbitt not marketed but used only when the relining done from the origi- nal melt babbitt bearing spe- cialists. the hundreds babbitt metal formulas, tin base and lead base, made the eombination tin, antimony, copper and lead, all them can well discarded with the exception three four which every sleeve-bearing requirement the present world machinery, from line-shaft bearing the main bearings diesel marine engine. And even now, the writer ventures say that per cent the machinery this country can get good bearing service with properly alloyed lead-base babbitt containing more than per cent tin prescribed the War Production Board. Cementing High Speed Steel Tips ECENTLY the Timken Roller Bearing Co. pointed out the economies affected using Cinch steel cement the cement- ing high speed steel tips low alloy shanks. This process was de- scribed article the April issue THE IRON AGE entitled “High Speed Steel Tips Cemented Low Alloy Shanks,” and also the June issue under the title “Cementing High Speed Steel Tips.” (Now available reprint form with other articles under title, “How Increase Cutting Tool Life,” 35c.) Since these articles were published, changes have been made that have either improved the bond reduced the cost. From the cost saving angle, has been found that SAE 1020 steel entirely satisfactory for shanks, except where high stresses are en- countered. Furthermore, saw and shaper will process approximately per cent the shanks and in- serts. other werds, very little milling machine work need in- 50—THE IRON AGE, November 1942 volved. Rough surfaces and some- what poor fits between the shank and insert are filled with the ce- ment. This contrast braz- ing where fairly good surfaces and fits are required. cases where the high speed steel insert entire- used and the shank long enough, the shank recut and an- other insert cemented on. From the standpoint proper bond, some trouble was encountered when cementing inserts made from molybdenum types high speed. The cement did not flow freely the lower high heat temperatures, resulting number failures from loose bonds, particularly flat formers requiring large inserts. After some experimenting, very simple solution was found: First, substitute thin water-boric acid solution for the copper sulphate paint binder for the loose cement. Second, add approximately per cent volume boric acid powder the cement, making sure that the boric acid well mixed with the cement before applying the tool. Chapin, maker Cinch steel cement, also has new devel- opment for the improvement the cementing process. been found that too much air has been the cause most cement fail- ures and suggests removing the tool from the furnace when reaches about 500 600 deg. F., just hot enough melt boric acid and powdered borax. powder called 90-and-10, consisting commercial powdered boric acid and oz. powdered commercial which temporarily removed from the furnace the temperature mentioned above. The boric acid and borax form seal which ex- cludes the air and makes perfect bond. applying the 90-and-10 powder mixture, best use salt shaker some other simple de- vice order completely cover all joints. The bond completed the high heat temperature suitable for heat treating the particular type high speed steel being tip- ped. HROUGH the tin content babbitt metal has been ordered reduced sharply typical analysis permitted un- der current conditions being per cent tin, per cent arsenic, per cent antimony and the remainder lead. This contrasts with bearing metal alloys commonly used and having tin content ranging from cent. The restrictions referred have been put into effect the United States and also Great Britain, and probably any manu- facturing carried any the other Allied nations faced with the same restrictions prospects. Besides reduction tin content, certain other restrictions have been imposed some instances. For ex- ample, the British Ministry Sup- ply has recommended reduction thickness bearing metal low 0.010 in. unflanged, thin wall bearings and that bearing liners should designed thickness 0.030 in. for bearings below in. bore, 0.040 in. for bearings in. in. bore, and 0.060 in. for bearings between in. and in. diameter. this country the thin walled bearing has been “the coming thing” many applications and had arrived automotive applications sometime prior the war. fact, steel-backed babbitt bear- ings used the automotive in- dustry are common usage with lining thickness only approxi- mately 0.006 in. Problems have arisen result these changes the technology bearing design bearing manufacture, however. With the thin backed bearings essential that firm bond between the bear- ing and the backing material ob- tained. With steel backed bearings this comparatively easy because the babbitt metal can united the steel after the steel “tinned.” This ease tinning does not pre- vail, however, where cast iron liners sleeves are used with babbitt metal. Another difficulty frequently en- countered that anchor holes anchor grooves are not quite practical with the thin babbitt bear- ing. has been common practice for many years provide anchor holes anchor grooves into which the babbitt allowed flow when cast iron backing used. Thus mechanical anchor, plus what little bond can obtained between the babbitt metal and cast iron, used retain the liner the backing. However, lack uniformity thickness the bearing metal where anchor holes grooves are used disadvantage, particularly with the thin babbitt bearing, be- cause lack uniformity stresses and wear. This has been one the principal motives behind microphotograph was taken section the junction the cast iron backing and the babbitt metal the bearing and shows very clearly the alloy bond obtained between the two. The specimen was unetched and the magnification 500 diameters. THE IRON AGE, November Bonding ron and ron and \ 2—Three diesel connecting rod bearing backs Meehanite iron. (A) the iron backing; (B) the backing after being dipped the Kolene cleaner, and (C) the backing after dipping Flo-Met'l and prior pouring the babbitt into the backing. the babbitt development the “tinned,” steel-backed babbitt bear- ing. (See paper “Automotive Bearings,” presented John An- thony, Cleveland Graphite Bronze Bushing Co., before the Society Automotive March 31, 1941.) Thus vital problem has arisen the bonding the babbitt the backing. The problem two-fold: First, involves the bonding very low-tin content babbitt bearing metal steel; second, involves the bonding bearing metal with cast iron. severe, but obviously the bonds with cast iron have been most dif- ficult obtain. solution has been advanced the Kolene Corp., Detroit, and has been accepted number con- cerns and being investigated cur- rently others. Within the WPB the problem has been encountered and results the Kolene process observed that any the firms newly encountering the problem 52—THE IRON AGE, November 1942 have possible solution indicated for them. The solution equally applicable with steel backed bearings and with cast iron. But the outstanding suc- cess with cast iron suggests that this processing discussed, with the understanding that the discus- 3—Three diesel main bear- ing backings Meehanite cast above. These are 9!/ in. and weigh each. The photo- graph (B) shows the means used handle the casting for dipping the cleaner. sion also applies steel backed bearings. the case cast iron, the solu- tion makes possible clean the cast iron that can be, effect, “tinned.” The cleaning process the first step and then the applica- tion alloy coating called Flo- follows. The alloy compound lead which capable dissolving iron seven per cent. This alloy, which only per cent tin, apparently forms interfacial bond alloy (see micro- photograph) with iron steel that will not peel chip. proper fluxing then possible pour babbitt metal and secure uniform bond between the coating and bab- bitt, even though the babbitt very low tin content. When pouring babbitt into these bearings after coating, desir- able pour while the bearing still hot; i.e., above the melting temperature the Flo-Met’l, which 480 deg. Tests bearings prepared * g a 4 ie this manner—without anchor holes —show that the shear strength greater than that obtained when the babbitt poured into anchor holes uncoated bearing (un- tinned). For example, tests made the Dodge Mfg. Co., licensee Kolene and one the largest producers power transmission bearings, showed that bearings pre- pared this manner had high 16,000 per sq. in. shear strength (average about 12,000 lb. per sq. in.), Whereas shear strength for similar bearings using anchor holes hold the babbitt metal place averages about 800 lb. per sq. in. interesting feature this process that makes possible accomplish the hitherto difficult impossible task “tinning” cast iron. Application this material steel backed bearings sible great saving tin since the tinning operation normally em- ploys high-tin content material pure tin while has only per cent tin according the manufacturer. The procedure followed clean the cast iron steel thoroughly the Kolene cleaning process (see “Metal Cleaning,” THE IRON AGE, July 24, 1941). This cleaning process consists first converting the surface impurities iron steel easily soluble form means hot catalyzed molten salt bath. This hot catalyzed mol- ten salt used burn the graphite from the surface cast iron. After rinsing, the bearing back then immersed reducing salt bath reduce the oxide placed the surface the first operation. After another rinse the bearing back Mustangs Service with British, who have done considerable amount air fighting and dying, have for years American aircraft. That the atti- tude not chronic best exempli- fied the fact that they have recently been extremely lauditory the American fighter, the North American Mustang. According Aeroplane, the Mus- tang now service with the Royal Air Force. Tomahawk the successor the squadrons. has already taken part fighter sweeps with Fighter Command over Northern France and has gained the approval all and sundry, from the A.O.C.-in-C., Army Cooperation Command, down the humblest flight mechanic. Time must confirm these early en- comiums. Its especial virtue lies its speed near the ground, but has whole catalog other good points. Its motor not supercharged for high flying, but that particular quality not essential its present job. Pilots who fly the Mustang praise lavishly that they exhaust their superlatives before they have fin- ished their eulogies. demonstra- tion its flying qualities and inspection its cockpit suggest nothing cast doubt the judg- ment those who might perhaps suspected looking with special favor something new. outward form the Mustang not unlike the Messerschmitt 109e, but has more graceful body. wears the fighter’s white spinner and white band near the tail, has thunderous roar, and sometimes whistles like Spitfire. Its climb phenomenal. seems rocket from ground level 5000 ft. with its nose only few degrees below the vertical—after fast dive. can rolled climbs—not once twice, but five times rapid suc- cession. spins with the ease and docility elementary trainer. has been looped and put through every other normal maneuver but has revealed vice. this re- sembles the Spitfire. control, the Mustang excellent. The ailerons are light but effective, and the elevators are positive all speeds. This equally true the unusu- ally steep glide with “dead” motor. heavy and robust, and will take hard knock without crump- ling up. Six eight strong men are needed lift its tail. Its long take- off run disadvantage these days prepared runways. With the motor rumbling the approved modern fashion the landing en- tirely devoid excitement danger. The Mustang’s Allison motor rated those who have flown other Allisons the best the series now service. reliable and smooth, and gives the ground crews headaches. immersed, usually for only few seconds, cold hydrochloric acid. then dipped through head flux into the Flo-Met’l, the high- lead, low-tin content alloy which, having the ability dissolve iron steel, actually forms facial alloy the and the iron steel uniformly over the sur- face the bearing backing mate- rial. While still hot, above the melting point Flo-Met’l, the bearing backing then fluxed and the bab- bitt metal poured the usual man- ner. The coating being high-lead content metal, easily bonds with the high-lead content babbitt metal, resulting uni- form, firm bonded bearing. With this firm uniform bond, the surface spots and other features present when anchor holes are used are eliminated. the RAF the layout the cockpit, the designer appears have remem- bered the pilot. The view good and the instruments are assembled neat, orderly rows rectangu- lar panel. many “gadgets” possible have been placed that the pilot may fly with his right hand and feet while attending other duties with his left hand. The control column simple stick, rather large, and carries nothing additional but the firing trigger— unfamiliar variation that the form trigger and not button. selector device al- lows the pilot fire the wing guns, the fuselage guns, all guns to- gether. The hydraulic brake pedals are incorporated the rudder pedals. The wheels retract inwards, like the Hurricane’s, and the period retraction about sec. The retracting and swivel- ing tailwheel can locked for take- off. Large plain flaps are fitted, but the Mustang can landed quite safely without them. They make little difference the trim. Other details are: Wing span, ft. in.; wing area, 236 sq. ft.; length, ft. in.; height, ft. in.; undercarriage track, ft. in.; motor, 1150 h.p. Allison F.3.R, V-type liquid cooled with single stage supercharger; Hamilton three-blade propeller, constant speed; armament, machine-gun wings and fuselage. THE IRON AGE, November 1942—53 : | | | A g — matic time-temperature con- troller the Automatic Tem- perature Control Co., Inc., Philadel- phia, emphasizes the growing importance recent trend to- wards strict control both heating and cooling stages during heat treatment. tions are demanding increasing use such control typified the Navy department specification S14 which reads part: “For carbon molybdenum steel piping after mean temperature 1100 1175 deg. reached, the piping shall held within that range for one hour and cooled 500 deg. rate cooling not over 125 deg. per hr.” From this specification can plainly seen that accurate control necessary. typical time-temperature pro- gram much more demanding nature than called for the above specification shown the graph, Fig. Such program might plausibly specified for various batch charges the heat treating furnace. Every stage the pro- gram from the initial raising temperature variety heating, soaking and cooling periods, all which are predetermined and auto- matically controlled conclusion, can accurately managed con- form with the most rigid and de- manding specifications. schematic wiring diagram the ATC means clarifying the mechanics the control instruments. The im- portant essentials the controlling equipment are the time-tempera- ture controller, suitable thermo- couple and recording control py- rometer. explain the functions these instruments controlling tempera- ture relation time, typical example controlled heating pro- gram cited. The sustained soak- ing periods consist mere main- tenance temperature, and cooling 54—THE IRON AGE, November 1942 stages are accomplished the re- verse the procedure for heating. The same accurate control main- tained all stages the same manner. furnace 1200 deg. the rate 100 deg. per hr. this instance the dial the slidewire gradu- ated from hr. and the rider arm the slidewire rotated from one end the other peri- hr. its synchronous mo- tor. The pyrometer’s control set- ting placed manually 1200 deg. and the slidewire’s rider arm manually set hr. adjusting the rate adjustment rheostat. The current through the slidewire in- creased until the rate meter reads 100 deg. per hr. this point the temperature control system ready start the program. OPERATION: the start, the e.m.f. generated the thermo- couple zero; the e.m.f. generated the time-temperature controller 1200 deg. These two e.m.f.’s are connected series, and are im- pressed across the pyrometer’s thermocouple terminals. This causes the temperature indicating pointer the pyrometer run immediately the 1200 deg. point the dial chart. Since the con- trol setting also 1200 deg. equilibrium exists the system. this point the motor started, and the slidewire rider arm begins lower the millivoltage the time-temperature controller. This motion uniformly actuated the synchronous motor. Since the milli- voltage set the time-tempera- ture controller now less than re- quired for 1200 deg. the pyrome- ter’s temperature indicating point- drops below the 1200 deg. mark and causes the pyrometer’s con- tact “make,” opening the fuel supply the furnace. This initial input fuel the furnace raises the furnace temperature and causes the thermocouple generate small millivoltage. This millivoltage added series with the reduced millivoltage the time-tempera- ture controller equivalent 1200 deg. and balance again restored the system the pyrometer’s temperature indicating pointer re- turning the control setting 1200 deg. general then, when the e.m.f. generated the time-temperature dredths millivolt, the coinci- dent effect the thermocouple increase its e.m.f. equal milli- voltage and thus restore balance the system. If, however, the initial input fuel the furnace caused ficient raise the thermocouple e.m.f. above few hundredths this millivoltage would cause the pyrometer’s temperature indicating pointer rise above 1200 deg. and thereby make contact—cutting off fuel supply. this way, the input the furnace regulated that the thermo- couple e.m.f. plus the time-tempera- ture controller e.m.f. always equals the level required for 1200 deg. the synchronous motor drives the slidewire arm down-scale, from thereby decreasing the e.m.f. generated the time-tem- perature controller, the pyrometer affected raise the furnace temperature sufficient amount increase the thermocouple e.m.f. point where, when added the time-temperature controller the aggregate remains the 1200 deg. level. Because the increase thermocouple e.m.f. all times bal- ances the synchronous decrease the time-temperature controller e.m.f., the furnace temperature in- creases linear function time. COOLING: After furnace has been brought heat, may cooled controlled rate and for given length time merely reversing the direction motion the slidewire’s rider arm. This inserted the thermocouple cir- cuit. Adding this new millivoltage the millivoltage the thermo- couple causes e.m.f. im- pressed across the pyrometer’s thermocouple terminals such magnitude cause the tempera- ture indicating pointer above the control setting. This causes the pyrometer make its contact, resulting decrease furnace input and cooling. this cooling takes place more rapid- than called for the settings the time-temperature controller, the pyrometer makes its contact order raise the heat slightly and remain step with the rate drop desired. Cooling Controlled the e.m.f. generated the time-temperature controller rais- causes the pyrometer reduce the input the furnace the desired rate until such timé the natural cooling rate the furnace slower than that the time-temperature controller’s rate cooling. This cooling operation the pyrometer has been brought room temperature until the cool- ing rotation the slidewire’s rider arm has been stopped, after defi- nite length time. the end cooling cycle, the pyrometer main- tains the furnace temperature the final point reached, similar its action the end heating Detail HIS photograph from the Ger- man paper Der Adler shows detail for the first time the form and method operation the “umbrella-type” dive brakes the tail the Dornier 217e2. Ac- cording Aeroplane, the principle the same that the tail para- chute, which has been used for some years safety device spinning trials. Apparently the four portions the brake open from the front and slide forward, the top and bottom sections being curved the sides maintain the contour the fuse- typical time-temperature program graph. Stage heat-up manually started and temperature rises uncontrolled rate 500 deg. Stage 2—At this point the pyrometer maintains the temperature 500 deg. throughout the soaking time hr. Stage 3—A controlled heating rate 500 deg. per hr. governed the time-temperature controller for hr. until tem- perature has reached deg. Stage 4—This another soaking time with temperature maintained 1500 deg. for hr. Stage 5—A controlled cooling rate 250 deg. per hr. effect for hr. until the temperature has reached 1250 deg. Stage 6—This soaking time with temperature maintained 1250 deg. for hr. Stage 7—A controlled cooling rate from 1250 500 deg. decreases the temperature the rate 250 deg. for hr. the end this time the furnace charge ready removed and temperature control governed the pyrometer for unlimited soak US. | BATTERY RATE ADJUSTING TYPE RHEOSTAT SLIDEWIRE EXTERNAL CONTROL RATE METER PYROMETER THERMOCOUPLE FIG. 2—Schematic wiring diagram the ATC time-temperature control system. the Dangling Dornier 217e2. lage. The photograph shown here deg. for normal bombing with in- from motion picture film the ternal stowage. brake opening. Pre- sumably the balance such the brakes can shut again after pull out, but jettison- ing arrangement incorporated that they can aban- doned necessary. The angle dive even with the brakes fully extended can- not exceed about THE IRON AGE, November 1942—55 TRIMMER RHEOSTAT ' ' ' ‘ ‘ ' ) > Pp RIDER ARM J + MOTOR e e l- Bs iS r- xe O- Separation Non- ON-FERROUS mation systems have been developed over period years. The foundation most them magnetic separation which, addition other recent improvements, now many cases permits separation mechanically entangled scrap, always difficult problem. Removal fine particles iron—fuzz, filings, etc., has also recently been made more effective. There are three main divisions non-ferrous scrap, for purposes discussion magnetic separa- tion: First, “junkyard” scrap, con- sisting old articles and pieces non-ferrous metal contaminated small degree with iron; sec- ond, non-ferrous borings and turn- ings which are contaminated relatively small amounts iron, and third, intimately associated entangled ferrous and non-ferrous scrap, such results when bab- bitted pillow blocks are bored grooved for lubrication channels. Junkyard scrap most common- separated magnetic pulley which installed head pulley belt conveyor system, pul- ley type separator which self- contained unit incorporating mag- netic pulley, endless belt, idler pul- ley, frame and motor drive. This type equipment applicable the requirements metal refining plants well junkyards. Pulley type separators can made port- able. The principle operation magnetic pulley illustrated Fig. Iron attracted the pulley and held fast against the Rotation Feed Revolving Shell \ iy Non Magnetic Discharge 56—THE IRON AGE, November 1942 Magnet Coils Magnetic Discharge com- mon type mag- netic pulley installa- tion. Equipment this type made replacing ordinary head pulley with mag- netic pulley. Stationary Magnet Poles IG. Drum type separator, consisting magnetic coil around which the drum revolves. Magnetic lines force extend only half way around the drum. belt until carried underneath and past the influence the mag- net zone. Non-magnetic material passes over the pulley normal trajectory. Magnetic pulleys are commonly built sizes ranging from 12-in. diameter face width, 48-in. diameter 63-in. face width. Approximate recommended pulley speeds range from r.p.m. for the smaller sizes down r.p.m. for the larger, with capacities ranging from approximately 400 cu. ft. scrap per hr. over 15,000 cu. ft. per hr. Pulley type separators are built standard, with ranging from in. 13% in. in. in. These are mounted with the belt horiz