The Iron Age 1942-11-12: Vol 150 Iss 20

NOV HOT ROLLED SHEETS COLD ROLLED SHEETS STRIPLATES TIN PLATE ELECTRICAL SHEETS TIN MILL PRODUCTS PORCELAIN ENAMELING SHEETS GRANITE CITY STEEL COMPANY Chicago Cleveland Denver Houston Indianapolis Kansas City Los Angeles Memphis Milwaukee Minneapolis Moline New Orleans New York St. | 7 c> | a | 3 | from the Production Lines for Vic TORY behind the Firing Citation War Gets More Pieces Per Hour The idea machining several bearing races from long piece tubing not new many operators but Toth, turret Tathe operator for Bantam Bearing Corp., South Bend, Ind., has added simple idea which enables him complete bearing race one chucking, this job the radius form the inner race must coincide accurately with the radius form the outside the same race. The drawings right show how, after the machine set with the necessary cutters the cross slide and cross sliding hex turret, gauge spacer used the tools the hex turret are all times positioned accurately relation with the cutters the cross slide. are glad send gold “Victory Pin” operator Toth for his initiative. response our request, hundreds turret lathe operators have told how their ideas and methods have saved time and mate- rials. Gold Victory Pins have been sent these operators recognition their re- sourcefulness and many their ideas are published Warner Swasey shop bulletin, Blue Chips. Make sure your operators are our list receive Blue Chips. sent free the homes over 38,000 turret lathe opera- tors. Write Warner Swasey, Cleveland, Ohio. TOOL TOOL CUTTER TOOL 7 You CAN TURN BETTER, FASTER. FOR LESS... WITH WARNER SWASEY WORK = 3 ROSS SLIDING RET TELY TURRET OCATE HEXA RET UNIT FROM SQUARE BORING BAR, BAR NOVEMBER 12, 1942 VOL. 150, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° ° Managing Editor, LIPPERT News Markets Editor, ROWAN Associate Editors Art Editor, WINTERS Editorial Assistants Resident District Editors Washington Pittsburgh Washington Cleveland Detroit OSGOOD MURDOCK 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 Robert Blair, 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 New York Peirce Lewis, 7310 Woodward Ave., Detroit 100 East 42nd New York . opin n Johnson, Market Research Hayes, Production Manager. Baur, Typography and Layout. ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. lished every Thursday. Subscription Price North America, South America and Possessions, Foreign, $15 year. Single copy, cents Cable Address Y." ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and 5éth 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 DUFFY CHARLES HEALE This Week Editorial The Sad Case Bertha Jones Technical Articles Roughening Surfaces for Recovery Gilding Metal from Clad Dornier Armoring Examined Forging 37-mm. High Explosive Stand-By Power for Gear Hobbing Acid and Basic Bessemer Refractories. Low Temperature Metal for Proof Casts. New Equipment: Machine Tools Features Assembly Line Washington West Fatigue Cracks Dear Editor News and Markets This Industrial News Coming Events Personals and Machine Tool Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Comparison Finished Steel Warehouse Prices Index Copyright. 1942. by Chilton Company (Ine.) THE IRON AGE— 133 135 136 138 140 142 146 209 ° ° ° UT-OFF 4 7 compliance with the government's request, are not privileged dis- close the nature this massive welded base—nor its use. exhibited here solely for the purpose focusing at- tention upon the character work en- trusted Mahon and the high calibre craftsmanship that goes into its fab- rication. When you call the experi- ence and resources the Mahon organization build your machine bases and frames, you can sure your blueprints will followed with exacting attention each detail and dimension, regardless size, shape design. With full allowance for the greater demands the war has brought about, this strict adherence quality largely responsible for the doubling and tripling Mahon production with- the past few months. THE MAHON COMPANY DETROIT CHICAGO 40—THE IRON AGE, November 1942 . Due our extensive facilities, are equipped arge volume work. Send your blueprints. accurately analyzed and quotations promptly placed your hands. Shipment assured earliest possible THE RON AGE NOVEMBER 12, 1942 ° ° ESTABLISHED 1855 The Sad Case Bertha Jones HERE was old play, patronized our forefathers, called “Bertha the Sewing Machine Girl.” this drama, rather, melodrama, the heroine beset with diffi- culties. much that the mellowist part the mellowdrama, she utters the never-to-be-forgotten words: help working girl night like What happened Bertha after this ejaculation not remember, for this play was staged before time and therefore probably before yours. hope, however, that everything turned out all right for Bertha and all wrong for the villain. hope too, that things will turn out all right for our modern Berthas; the white collared clerical workers who now come under the ukase our economic dictator, Mr. Byrnes, who has decreed that all increases salaries for our clerical workers, men well women, must approved the War Labor Board. Poor Bertha Jones, and poor War Labor Board! God help them both day like this: For both them are going have their full share trouble. You probably have some these white collared workers your organization. Some them are beginners who have been with you for six months more and who have made good their jobs. Others are who have had longer service and have had new responsibilities imposed upon them. You would like keep these people. But keep them, you must, from time time, increase their wages their ability and responsibil- ities increase. Otherwise somebody else will grab them off, and per- fectly legally, starting salary equivalent what they should now, because their added experience, getting from you. your recourse, apparently, submit these requests for deserved increases the War Labor Board. And this, too, the recourse thou- sands other concerns who are not seeking for horizontal increases, such the CIO and the AFL have readily obtained, but for few dollars week month individual cases. seems that the War Labor Board has too much wish upon the job deter- mining whether Bertha Jones, clerk the XYZ Co., not entitled raise 75c. week. Certainly the board has had its hands full ad- judicating right from wrong, vice versa, such cases U.A.W. versus General Motors U.S.W. against Little Steel. How have the time handle these big horizontal cases involving millions dollars year and take the little individual cases the white collared clerks who deserve raise and who not pay dues union moot question. relieve this situation for both the War Labor Board and Bertha Jones, why not empower employers grant such increases are de- served their judgment and individual cases, limit per cent above the pay received for the same work months ago, without submission the War Labor Board? After all, white collared workers are people and are entitled the same treatment that the board has given organized groups. 4 j | ° ° ° ° | | La 3 -& ne Credit given the Great Northern Railway for the illustration and theme this advertisement. STEEL STEEL Steel cars and locomotives, traveling swiftly and safely steel rails, are moving the greatest volume traffic the history our nation. This the war job the American railroads—a job already 60% greater than World War and handled 39% fewer locomotives and 17% fewer freight cars. This inspiring railroad performance made pos- sible foresight railroad management, alert- ness railroad operators, cooperation American shippers—and steel steel. the days before all-out war effort, Inland helped the railroads prepare for the present emergency Vth supplying large tonnages sheets, plates and shapes—special low-alloy, high-strength and rails made the control-cooled process. These Inland products helped build more powerful loco- motives; freight cars with less dead weight, higher payload capacity, and longer service; and tracks that are safer for higher speeds and heavier traffic. Yes, steel steel that carrying more than two-thirds the nation’s traffic, the greatest all time—the railroads’ part winning the war. Let all our part releasing cars quickly the greatest possible use can made all rail- road equipment. WLLL y, ‘Mad Dearborn Street, Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas ° ° COWAN Surface Combustion Corp., Toledo ° ° unrelenting demands the war effort for iron and steel have placed tremen- dous burden upon the nation’s open hearths, blast furnaces and cupo- las. means increasing the productive capacities these units, and for obtaining higher quality metal, attention has been directed more exact control the moisture content the air blast required operating such equipment. metallurgical operations where carbonaceous fuel brought into direct contact with the material be- ing treated and which the fuel supplies heat combustion with the air, the importance control- ling the moisture content the air has long been recognized, and the problem controlling this mois- development equipment which will give close and flexible control over the moisture and which will capable handling large volumes air economical production basis. effective answer these re- quirements has been found the development recent years chemical lithium chloride* the moisture control medium. This system has proven *See Iron July 30, 102, for description Kathabar and other moisture removal systems. sufficiently flexible and effective for applications common the iron and steel industry. typical installa- tion for handling cupola blast 8000 cu. ft. per min., shown Fig. There are four types metal- Effect last Air With renewed interest being shown the removal moisture from the blast air blast furnaces, cupolas, open hearths and bessemers, this article especially timely. this, the first two-part article, the author reviews some the basic conceptions combustion, with particular reference cupola operation, and traces the development thought moisture control. The little understood effect hydrogen the blast cov- ered, and specific examples the influence moisture content are given. lurgical operations that can di- rectly benefited controlling the moisture content the blast: The blast furnace; the cupola; the bessemer converter and also, for special reasons, the open hearth furnace. each case air used principally for the oxygen con- tains, since this reacts with carbon cause combustion and the libera- tion the large amounts heat upon which the operation depen- dent. the blast furnace and the cupo- la, the carbon present the form coke, but the bessemer con- verter carbon only one the con- stituents removed, with others, from combination with the iron. the same time, the com- bustion these materials supplies the temperature necessary for re- action. these processes, although air used principally for its oxygen experience that fluctuations occur operating these units which are not due oxygen alone. has been noted that these differences occur largely between wet days and dry days and between summer and win- ter. long ago June 11, 1800, the following notes were made pa- per Dawson: “In the summer season all know that the fur- naces never work quite well any other time. change from dry moist air has sometimes re- duced our charges four five hr., and changed the metal from rich No. very indifferent No. 2.” this quaint language pointed out the fact that the melting rate lowered and the metal quality changed increase moisture the air blast. Incidentally, this paper Daw- son such historic importance that was reprinted the British Iron and Steel Institute 1907. These variations which Dawson noted are traceable directly the moisture content the air, and this THE IRON AGE, Novemebr 1942—43 Rr 4 5 ° ° ° & ~ q i 3 has been well recognized that many cases has become custom- ary make periodic moisture de- terminations serve basis for altering operating procedure. one plant known the writer, the amount coke used the cupola charge was changed from time time the basis hygrometric readings that were made hourly. the basis experience, certain ar- bitrary standards had been set stabilize the operation this cu- pola and make independent the weather. now proposed make use moisture control equipment accomplish this stabilization and supply air definite moisture content the cupola. Stabilization Required The percentage moisture that the product that being made and the physical properties that are desired the metal. stabilized operation this kind will result the saving considerable coke, will eliminate the necessity for periodic moisture determinations, and will improve the physical properties the metal. These points will dis- cussed later this paper. first consideration might appear that the effects moisture the air could eliminated the use coke. such were at- tempted, the oxygen the water would combine with the carbon the coke, and the high tempera- tures involved would simply take part the combustion reactions. this respect the use water would replace air the usual combustion process. This viewpoint seems very widely held the industry since common practice use coke overcome moisture. must stressed, however, that addition those reactions which take account only the oxygen con- tent involved, hydrogen also lib- erated from the water and itself this will have far-reaching effects upon the physical properties the metal. This does not take into con- sideration the fact that high tem- perature required bring about the reaction between water and coke and that additional coke re- quired maintain the temperature the operation. This will noted terms practice when re- called that steam used certain combustion operations hold down the high temperatures that would otherwise result. metallurgical operations being considered here first (the cupola and blast furnace) the chemical constituents the water are liber- ated under conditions extreme reactivity and direct contact with liquid iron. well known fact that when chemical compound such water breaks down, the con- stituents which composed are that moment extremely reac- tive and enter easily into combina- tion with other chemical elements the vicinity where the reaction blast furnace operation, the typical cupola installation equipment for controlling the moisture content the blast. The unit shown Kathabar installation capable handling 8000 cu. ft. air per min. 44—THE IRON AGE, November 1942 CHARGING FLOOR 8000 CFM Ho 08 | 109 COOLER 140 GPM 75° WATER & Sia DB. HEATING MOIST AIR DISCHARGE e 150 D.B. 8000 CFM OUTSIDE AIR CONTAC TOR coiL REGENERATOR 26.2 ‘ 1310/HR. STEAM 4 20,000 18,000 16,000 2—Effect moisture coke chart shows the amount coke which must 10,000 charge compen- crease the mois- ture content the blast. 4,000 ° ° ° moisture which enters the furnace with the blast through the tuyeres reacts with carbon and liberates hy- drogen the ideal point and ideal condition absorbed the liquid iron which this mo- ment has reached its maximum tem- perature. Types Moisture The moisture that introduced this manner must not confused with moisture introduced the solid charge the furnace damp coke other materials the bur- den. this latter case, the mois- ture enters the furnace the top and driven off low tempera- ture with the top gases while the charge being heated. The moisture which enters the tuyeres the blast furnace, how- ever, ideal form and the ideal spot for adding hydrogen the melted iron. The same thing may said regard cupola operation. the case the oper- ation the bessemer converter, becomes apparent once that the intimate contact which afforded there between masses melted iron and large volumes air which are blown through the iron, provides excellent means for introducing hy- 400 VAVAVAVAVA BLAST | } } | BASED STAND. COND. | | 800 1200 1600 2000 2400 2800 3200 LBS. COKE PER HOUR 3600 4000 1.5 Grains per cu. 10.4 Grains per cu. ft. 21.2 Grains per cu. ft. 3—Effect moisture depth chill cast iron. These specimens are from the respective heats tabulated Table THE IRON AGE, November 1942—45 GRAINS WATER PER CU.FT. BLAST 7.7 > Chilled Face Sand Cast Face & Pw x Chilled Face 21.2 GRAINS WATER PER CU. FT. Sand Cast Face 001) (100 icrographs These Tabl icrostructure gray iron. and analyzed “ 25 ture 4—Effect small amounts mois diameters) are from the Grain Moisture Grain Moisture Fig. (500 diameters) the edge the iron shown Fig. drogen into the metal from the moisture contained the blast. The use dry blast connec- tion with the operation blast fur- 48—THE IRON AGE, November 1942 naces and cupolas not new; has been used this country and considerable fund literature has accumulated this subject through the years and many claims have been made which have been found extravagant. 1904, James Gayley built the first refrigerating plant freeze the moisture out the air for the blast one the Isabella blast furnaces the Steel Corp. Etna, Pa. Following this, some installations were made various parts the coun- try. Installations were also made Germany and England, but the results obtained that time were such that practically all these plants were finally dismantled. each these cases, the mois- ture the air blast was removed refrigeration the form ice and consequently involved the re- for each hr. operation. There seemed question but that coke was saved blast furnace op- eration and that the furnaces were made operate more smoothly this treatment. The principal draw- back appeared the mechan- ical operation the refrigerating equipment and the difficulty ob- taining uniform and consistent op- eration. number installations for drying cupola air have been re- ported. each case the results ob- tained have shown improvement that their use has continued throughout the years, although the idea has not taken hold the in- dustry large. The reason for this case, the type equipment avail- able for this work. Blast moisture control, applied the operation bessemer converter, believed new thought arising from consideration the presence hy- drogen this metal. possible fourth application con- cerns the open hearth for steel making. There sufficient evidence show that hydrogen steel traceable the melting operation. This matter will considered more fully later this paper. Returning more detailed con- sideration these processes, the use blast air which the moisture content controlled with- definite limits and moisture com- position uniformly maintained, re- gardless atmospheric conditions, these processes the order named, first the cupola for the manufacture t gray iron, then the blast fur- nace, the bessemer converter and the open hearth furnace. Cupola Operation edge that the operation foun- dry cupola dependent upon the weather. the day dry one, the air entering the cupola will low moisture and this will have beneficial effect upon the tion. the other hand, the moisture content the air high, the operation the cupola ad- versely affected. These facts themselves many the ups and downs encoun- tered cupola operation. During the winter time, the moisture con- tent the air usually low and this checks with the common ob- servation that the operation these units more uniform win- ter than summer. During the summer season, the moisture content air suffers wide series fluctuations that of- ten occur rather suddenly and, times, during the course single day. These changes often result upsetting the cupola operation. This fact well recognized that has become good practice the opera- tion cupola plants take peri- odic moisture readings the air used the blast. the basis this content adjustment made the coke charge along with the necessary volume change the amount air used. The procedure requires constant attention and supervision insure satisfactory results. Thus, ob- vious that the best type cupola operation obtained under condi- tions that are maintained uniform all times. When becomes neces- sary change any the factors, such air, fuel, burden, etc., the functioning the cupola altered and time required stabilize conditions the new basis. However, these changes are made frequently throughout the necessary when the moisture con- tent the blast varies, obvious that while the results may kept satisfactory from the standpoint metal quality this will have been ac- complished the expense con- siderable adjustment. Always pres- ent the danger producing iron intermediate indifferent qual- ity. fact, these frequent adjust- TABLE Effect Moisture Chemical Analysis Gray 21.2 2.64 0.95 0.70 0.136 0.163 1.42 10.4 2.92 0.82 0.83 0.144 0.162 1.58 1.5 ments are largely responsible for the production off-quality metal. Coke Consumption The amount moisture the cupola blast affects coke consump- tion very definite manner, act- ing increase coke requirements the moisture content the blast rises. This shown graphically Fig. This chart, prepared the Battelle Memorial Institute, shows the amount coke that must added the base charge com- pensate for given increase moisture content the blast. This chart read the follow- ing manner, assuming cupola re- quiring 11,000 cu. ft. air per min. this air contains seven grains water per cu. ft., coke the amount 800 will have added the base charge. this blast contains 10.5 grains, 1200 coke will required, addition the base charge. The fluctuation the moisture content the air actual practice can very sharp. variation grains per cu. ft. may observed between different days and occasionally within the same day. apparent from this chart that increase the moisture the blast requires increase coke charges order maintain the metal temperature. This has far reaching effect upon the entire operation. the first place, will supply additional carbon react with the oxygen the water and, since heat necessary produce this reaction, this will affect the temperature the metal. The varied temperature, turn, will al- ter the chemical composition the metal being produced. The effect moisture upon tem- perature may illustrated many different ways. the operation the bessemer converter, steam sometimes added the air blown through the molten metal hold down the temperature reaction. 0.71 0.79 0.122 0.144 1.77 And, certain experiments the melting malleable iron, the effect moisture added the blast reverberatory furnace has served lower the temperature the result- ing iron. The effect was the same when moisture was added the coal used for fuel, either addi- tional moisture moisture locked the structure certain types coal. illustrate the effect mois- ture upon the chemical analysis gray iron, the result run cupola which all conditions were maintained constant, except the moisture content the blast, shown Table The table shows that the mois- ture content increases, the total car- bon content the metal decreases, the silicon content decreases and the combined carbon increases con- siderably. These facts indicate that the iron has increased substan- tially hardness. The effect this upon the depth chill shown Fig. photograph the frac- tures the iron covered Table actual measurement, the chill depth increased from 0.75 in. 1.5 in. with the increase moisture. The differences the correspond- ing microstructures this iron are shown Fig. These micrographs also provide comparison between the sand-cast and the chilled face the same iron bar. The wide difference these structures, result the differ- ent moisture contents the blast, clear illustration the effect that moisture has the operation cupola and the resulting prod- uct. Records show that the tem- perature this metal was lowered, result the increase mois- ture content, from about 2580 deg. 2480 deg. with the higher moisture value. This lower tem- perature affected the melting rate adversely. another case, manufacturer THE IRON AGE, November 1942—49 | | | j ig | { piston rings found that the rings became white and hard when the moisture content the blast in- creased above certain minimum. The structures resulting this case are shown Fig. The spec- imens the bottom are unetched. detail the edge with the higher moisture content iron shown 500 diameters Fig. increase the moisture content the blast from grains per cu. ft. was sufficient cause the difference these rings shown the micro- graphs. not intended convey the impression that variations this kind are looked for castings coming from gray iron foundries. The men who operate cupolas know how, manipulation, take care these variables and part the art cupola operation de- tect quickly possible the ad- verse developments they occur and make adjustments necessary compensate for them. There are times, however, when this extremely difficult and all times its success dependent upon the personal element, most vari- able factor. These variations can met and maintained far sim- pler manner controlling the moisture content the blast and holding definite value which has been determined experience. Such procedure can established very simply. Editor’s Note: Next week, conclu- sion, the author discusses the effect moisture the air used blast furnaces, open hearths and bessemers, with par- ticular reference the influence hydrogen high-moisture blast the characteristics iron and steel. Roughening Surfaces for Metallizing OST types sprayed metal not form chemical bond with the coated part, and get good adhesion necessary roughen the surface secure mechanical bond. Over the past year two number tools were developed roughen surfaces. They included specially knurled and dove- tailed tools, and did satisfactory job when the material was easy machine and tool life was great enough stand the relatively high cost. These special tools did not prove satisfactory, however, alloy steels. Engineers the Carboloy Co., approached with the problem, came the conclusion that while cor- rectly ground Carboloy tool will produce smooth surface, in- correctly ground one would produce the reverse. Selecting style tool from stock they ground the unorthodox shape shown Fig. Fig. shows the results achieved machining piece tough alloy steel, taking cuts depths 0.101, 0.015 and 0.020 in. respectively. The feed was approximately 0.030 in. Cutting speed was between 200 and 250 surface ft. per min. The surface the extreme right that produced the 0.020-in. depth, and was exactly what the metallizing men were looking for. cutting, the “improperly” ground tool raised burr between the tool marks, and the tool angle was such that the cutting tool pressure pushed the burr over into horizon- tal position. The photograph, Fig. 50—THE IRON AGE, November 1942 and the sketch “C” Fig. show that the tool also lifts some the crests intermittently, thereby CARBOLOY TOOL GRIND OFF WITH SILICON CARBIDE WHEEL SPECIAL TOOL FOR MACHINING SURFACES ABOVE tool for machining surfaces metallized, produced unorthodox grinding standard Carboloy tool. RIGHT 2—Alloy steel shaft ground experimen- tally determine surface roughening ef- fect different depths cut with spe- cially ground roughening tool. hesion sprayed metal. producing mottled surface that forms ideal base for the ad- ° ° ° nlarged profile face prepared for me- FEED 030 sprayed metal coating. FEED PER TOOL OUTLINE SURFACE OF CUT REVOLUTION | | 7 J save alloy, the Ordnance Department has decided use brass-clad steel for bul- let jackets place the custom- ary solid brass (gilding metal) formerly used.* The cladding will *See Ace, July 30, 85. contain per cent copper and per cent zinc, the same the solid gilding metal, and will amount approximately per cent the weight the material, the remain- ing per cent being mild steel. the production the bullet jackets, considerable scrap will produced; esti- mated that its will amount 11,000 tons month May 1943, when maximum pro- duction probably will reached. Part this scrap will steel-mill scrap; part will webbing, and lesser amount will from cup- forming operations. Superior Steel Co., Pittsburgh, already pro- duction clad jackets and has al- ready accumulated large tonnage reject pieces. Other companies are also starting produce, and scrap believed have been accu- mulating the rate about 1200 tons month. Companies now pro- are: Superior Steel Co., Weirton Steel Co., Steel Co., American Steel Wire Co., Sharon Steel Corp., Allegheny Lud- lum Steel Corp., Acme Steel Co., Republic Steel Corp. and McClouth Steel Co. The rapid piling this scrap with developed program for its recovery serious concern those responsible for the country’s copper and steel production. va- Recovery Gilding Metal Clad Steel ... the streams bullets pour from the munitions fac- tories, the pool gilding metal clad scrap grows. con- tains steel, zinc and desperately needed copper. This ‘study, made the request the WPB, surveys methods and possibilities recovering the metals this pool scrap. riety recovery processes which Battelle Memorial showed promise have been tried: but there only one oped and practical process now available. This, the cupric ammo- nium carbonate process, stand- ard leaching procedure applied copper ores. The process based the sol- vent action cupric ammonium carbonate copper and and has been shown workable the clad material. cheap and efficient method which will allow for almost complete recovery the copper and the iron separate products, the copper the form the oxide and the iron tacked scrap. The recovery zinc remains the most unknown factor and may poor unless addi- tional leaching treatment formed the copper precipitate before smelting. Method Use The process has already been demonstrated pilot-plant scale, and starting commercial produc- tion will for the most part depend upon the availability men and THOMPSON Metallurgy Committee National Academy Sciences materials. Fur- Institute and War ther experimental work pilot plant testing not deemed necessary. The not new, and all the metallurgical operations involved have been prac- ticed successfully for years. Good recoveries and clean separations the copper and iron are possible, and the operating costs are reason- ably low. Three known companies this country have had experience with the leaching gilded steel the cupric ammonium carbonate meth- od. These companies are the Calu- met Hecla Consolidated Copper Co. Lake Linden, Mich.; the American Metals Co. Carteret, J., and the Copperweld Steel Co. Glassport, Pa. Calumet Hecla have operated for many years cupric ammonium carbonate leaching plant the treatment copper ores. They also have, for the past couple years, commercially treated copper-clad steel and have experimented laboratory scale with the process- ing gilded steel scrap. the present time, their Lake Linden THE IRON AGE, November 12, ri- m- es, ‘ q ig | ULLETS like those this Flying ammunition feed belts used have caps solid gilding metal. Now save copper and zinc, nine companies are, soon will be, producing gilding metal clad steel for bullet caps. plant Michigan, they have ca- pacity treat 2500 tons per month gilded steel and are ready and willing accept this amount material immediately. They have additional capacity 7500 tons monthly for the leaching metal scrap, but oxidizing equip- ment for the treatment the addi- tional material would have built. They have existing smelter capacity handle the entire ton- nage copper oxide which should result from the processing 20,000 tons gilded steel per month. Although recovery would made under the pres- ent operating conditions the plant, such additional recovery plant could installed. The Copperweld Steel Co. has, for number years, experi- mented with the recovery the copper and iron from the scrap made the company’s own plant. now has pilot unit under con- 52—THE IRON AGE, November 1942 struction for the treatment some its own clad material. The American Metals Co. oper- ated ammonia leaching plant for number years recovering zinc from flue dust Carteret. The estimated recovery the steel the ammonium carbonate method 100 per cent; copper 96.5 per cent. The amount zinc recovered would depend upon the subsequent treatment that per- formed upon the mixed copper and oxides which are the end prod- ucts the ammonia leach. leach- ing scheme has been proposed the Copperweld Steel Co. for the sepa- ration the zinc oxide from the copper oxide, using caustic soda treatment, but doubtful this would practical procedure. The recovery will probably have depend upon that obtained flue dust the smelting the mixed oxides for the recovery the cop- per. One company has estimated that 82.5 per cent zinc can recovered impure zine oxide this way. any case the amount would not all practical con- sider its subsequent treatment other than existing zinc smelters electrolytic plants. While unlikely that the would ob- jectionable the steel, thought that were not removed, the at- tack refractories, particularly the checker work, would serious. addition, the would lost. The three companies mentioned above are all considered qualified construct and operate cupric am- monium carbonate leaching plants for the treatment gilded-steel scrap. Aside from transportation, Calumet Hecla are probably the best position carry the work constructing additions their present plant. standpoint transportation, ap- pears that the Cleveland Pitts- burgh area the best location for plant the construction sin- gle central unit contemplated. The cost constructing plant treat 10,000 tons the scrap month estimated $1,500,000 $2,000,000. Cost operation about $5.21 per ton scrap. The over-all charge against the copper, oxide, would about 2.50c. per There would additional charge 3c. lb. the con- version the oxide electrolytic copper forms. Shipment the oxide serious problem. The steel resulting from the am- monium leach should clean product. this material were com- pressed into bundle, could prob- ably classified No. bundle taking price equivalent No. heavy melting steel. far preparation the clad Reclamation and Conservation Metals ... This No. series articles designed aid industry obtain the utmost value from every pound metal. q scrap before treatment concerned, the American Metals Co. has sug- gested that the pieces cut into approximately 6-in. squares, and gether flat surfaces. Calumet Hecla prefer the webbing rolls, not only convenient form for leaching, but also for charging into open hearths when metal has been removed. case should the material baled. Less Successful Methods which were considered developed past experimental stage, and none them showed any worthwhile advantages over the ammonium carbonate leaching method. However, electrolytic methods have been considered three com- panies. The American Metals Co., Carteret, experimented with the recovery the copper, using ammoniacal electrolyte. Difficulty was encountered the plating out the copper. The metal went into solution readily enough, but only about per cent could de- posited the cathode surface. The trouble was attributed surface oxidation, and was thought that might overcome maintain- ing film oil over the surface the electrolyte. However, there seems simple and efficient way handling the scrap anode material, and excessively large elec- trolytic tank areas would re- quired. The Automatic Gasflux Co., Cleveland, has had mind the treatment this scrap electrol- ysis cyanide sulfate bath. Rough production cost estimates around 10c. per lb. recovered cop- per were obtained, but insufficient work has been done establish definite cost figure. The Copperweld Steel Co. has also worked with electrolytic recov- ery methods, with conclusions simi- lar those the American Metals Co. The American Metals Co. spent considerable time from May through July this year trying develop suitable scaling pro- cedure. The method consisted heating the gilded scrap tem- perature somewhat below the melt- ing point the alloy and water-quenching from this tem- per cent the copper and zinc metal and metal oxide scales. second scaling treatment resulted practically additional recov- ery. Leaching tests were conducted the scaled scrap. was considered the first place, because was felt that ammonia ammonia salt might one-half the daily consumption ammonia still indicated the factual data, but because the slowness with which the copper dis- solves from the heat-treated scrap, the amount ammonia required start plant remains approximately the same. The initial requirement the big item far ammonia concerned. The Copperweld peo- ple also studied scaling with simi- lar conclusions that the method has particular merit. The Copperweld laboratories also worked with sulfide scaling pro- cedure. The bi-metal dipped into molten sulfur, and the copper sul- fide formed ground broken from the iron core. was said that copper sulfide layer 1/16 in. thick formed min. The sul- fide brittle and easily scaled broken from the iron. Information indicates that the resulting steel high sulfur that almost worthless. The process still the experimental stage, and cost figures are available. addition the above-men- tioned procedure, the Copperweld Co. has experimented with ammo- nium sulfate leaching agent. The copper dissolved from the iron with the ammonium salt and precipitated from the leach with sulfuric acid. Copper sulfate re- covered, and the reformed ammo- nium sulfate returned the leaching circuit. The sulfuric acid which consumed the precipita- tion stage could recovered the copper sulfate were subsequently treated electrolysis. While this process simple and undoubtedly workable all its phases, would require time develop, and offers essential advantages over the ammonium carbonate method. Note: Since receiving this re- port, the has arranged for Calumet Hecla receive and treat 2500 tons gilding metal clad steel scrap month. The copper and steel are being reclaimed, but the zinc. The com- pany has not been authorized increase its capacity, pending study the govern- ment other methods and sites men- tioned this report. Dornier Armoring Examined ITH eye keeping in- formed the enemy’s prog- ress for their flyers, the armoring Ger- man Dornier 217e-1 been examined determine its composition, gage weight. These facts are not only interest- ing from the metallurgical stand- point but also key the amount dead weight being im- posed the carrying capacity the newer types German planes. The three pieces armoring re- moved from the Dornier for exam- ination were pilot’s seat back, curved plate from the upper por- tion the fuselage and trans- verse bulkhead. The pilot’s seat back proved welded component, mm. thick and weighing 126 lb. It’s chro- mium-silicon-molybdenum steel con- taining 0.49 0.96 Si, 1.49 and 0.23 Mo. diamond pyramid hard- ness test shows hardness number 434. The plate from the fuselage was thick, and weighed lb. analy- 1.33 Si, 1.13 and 1.08 Cr. The diamond hardness reading this sample was 559. similar investigation the bulkhead showed thickness mm. and weight lb. Its dimensions were 20% in. The chemical composition and hardness were similar the fuselage plate. The microstructures each sam- ple showed tempered martensite with the surface the plates de- 0.0025 in. The surfaces counter- sunk holes also were found decarburized, indicating that the holes had been drilled prior final heat treating. The composition the three samples examined were different from those other German armor plate previously examined closely approached the composition armoring taken from Messer- schmitt 109. the Messerschmitt the composition was 0.46 0.6 Si, 1.35 and 0.55 Mo. Most notice- mium-molybdenum steels found samples and (the pilot seat and bulkhead) was the somewhat higher than usual content. THE IRON AGE, November — - SS — | ‘ 7 | | | | | | { Sawed proportion bar now used make 37-mm high explosive shell—gross weight (Right) inside and out- shell besides several machining operations. great network small manu- facturers are helping pro- duce the needs our Army and Navy. Among these small plants the Portland Forge Foundry Co., located the heart the Midwest typical small American town with population approximately 6000 people. Here with few hun- dred employees are produced va- rious types forgings, all which help make the sinews war. the fall 1940, one year be- fore Pearl Harbor, this plant de- veloped new forging technique which was worthwhile contribu- tion our national defense pro- gram. (THE IRON AGE, Oct. 16, 1941, 35.) was one the first production basis, the trench mortar shell forging completely nosed, thereby cutting out the rough machining and nosing opera- tion which was performed the machiner. Since that time the com- pany’s engineers have assisted nu- 54—THE IRON AGE, November 12, 1942 merous other plants throughout the nation solving their problems shell production. From coast coast the War Pro- duction Board has been pleading with industry conserve metal and save scrap. The Portland Forge Foundry Co. has developed, after several months experimenting, 37-mm. high explosive hollow shell forging which should save millions pounds steel. Heretofore this shell has been made from bar stock with the machining waste equal almost much the weight the finished shell. First, the stock had drilled and reamed form the inside cavity. Secondly, took several minutes rough the stock off the nose end before finish cut could taken over the entire contour. Besides the saving steel, this newly developed forg- ing will save the drilling the in- side cavity and the roughing the nose end (Fig. which turn will greatly speed production. The process used the making Forging 37-mm. High this shell not new most manufacturers forged shell pro- jectiles. However, many the practices used produce the larger caliber shells had abandoned. The thought making forging with thin wall section having hole less than in. diameter and over in. long did not appeal the forging industry, but when na- tion war and metal more precious than money, the ingenuity man usually brings forth devel- opments which under normal con- ditions would not come into exist- ence. The forging was produced old 3-in. Ajax upset forging ma- chine using the upset method (Fig. 2). Most the work and experi- menting was performed the men after their regular working hours that the production other vital war materials would not affected. The shell forging completed five passes shown Fig. The shell bars are sawed lengths suitable for forging shells which are upset from each end the bar. The first punch and die upset the stock and neck-in the middle the bar. This preliminary upsetting and nicking the stock done order assure the proper center- ing and forming even collar which necessary the following operations for sound concentric forgings. The second punch pierces the billet and forms collar the upset end while the nippers further reduce the necked-in part. The third and fourth punches gradually expand and elongate the cavity the forging the nippers continue reduce the necked-in part 34-in. diameter. the last fifth pass the shell cut from the bar placing the stationary die, using the collar the front end gage. blade the mov- ing die (shown Fig. cuts the shell exact length the dies close, then inserts into recess the stationary die completely close the end the die the punch enters for the final piercing opera- tion. The collar the front the forging then acts stripper when the punch withdrawn. The Explosive Shells shell drops from the cavity and rolls out the side the machine (Fig. 2). small punch press placed the side the machine, making convenient for the press operator trim the collar off the shell. The shells are then given 100 per cent inspection with various gages determine the amount ity, ellipticity, ete. simple the setup that only four men are actu- ally needed produce the forging, namely: The forging machine oper- ator, the heater, the press operator and the inspector. The tool and die life not the problem one would expect with the punches less than in. diameter and the final piercing tool over in. long. The punches are designed that only small part the nose each actually does the piercing. Since only minute part each 2—An old type in. Ajax forging machine. the machine after they are cut from the bar. CHARLES BARRENBRUGGE Designing Engineer, Portland Forge Foundry Co., Portland, Ind. small firm who pioneered mortar shell forging job has come through again difficult upset forging which the final punch less than in. diameter and over in. long. Other articles shell forgings are reprinted “Munitions and Ordnance Manufacture," price $1. punch contact with the hot metal, absorbs very little heat and this dissipated regu- lated flow coolant over the tools. Regulating the proper amount lubricating solution over the dies and punches control the tempera- ture each was one the factors which made possible the forging this small caliber shell. The first four punches are made from treated alloy die steel, and are not heat treated after machin- ing. The fifth punch made from shell die (made Finkl Sons Co., Chicago) and treated hardness about scleroscope. The dies are made Hardtem (Heppenstall), treated before ma- chining and the cut off blade Kloster DC-33. The dies can made two dif- ferent methods and both have their advantages. First, the impressions can machined solid block (as shown Fig. copied from Note the shells falling out the chute the side the background can seen the oil fired furnace used heat the steel billets. THE IRON AGE, November 1942—55 | | | | | aq j a i a é 4 “ Fi 1G. 3—Progressive steps the forging 37-mm. shell upset forging machine. Two shells are forged from each bar. The only loss material the small piece shown the lower right hand and the collar trimmed from each forging means small master die Keller machine. This type die easy resink merely cutting 3/16 in. off the face each block and resinking the Keller. great deal die ma- terial per resinking can saved this method; however, should one impression wear more than an- other, would necessary re- sink all the cavities. The other method uses solid block with in- serted cavities and nipper plates. punch press. The nippers are made one strip and inserted vertically the die. Each cavity fitted with half round insert. These are bored profile attachment. These in- serts and nippers can replaced indefinite number times. oil-fired furnace used heat the steel billets tempera- ture 2000 deg. Since the steel billets required are small eter, they heat very rapidly. There- fore, one medium-size furnace will supply enough steel keep the up- setter running top speed. This Midwestern plant only one the many thousand small in- dustries throughout the country that are helping eliminate many bottlenecks and shortages mate- rials, thereby bringing about in- creased production vital war im- plements. 1G. 4—The dies and tool holder are made one piece. The punches are fitted that they can changed very few minutes. the lower pass the moving die can seen the blade which cuts the shell from the bar before the final piercing tool enters the cavity. 56—THE IRON AGE, November 1942 : Stand-By Power for Gear Hobbing Operation equipment, manufactured the General Electric Co., has proved successful eliminat- ing time losses due power fail- ure and reducing costly spoil- age gear hobbing operations marine speed reduction gears stand-by power volts), for not less than hr. Ex- perience showed that power fail- ures would not extend beyond this length time. Other requirements were: In- stantaneous and automatic trans- fer stand-by normal source and from normal stand- GENERAL view the stand-by power equipment installed the Laval Steam Turbine Co. General Electric, showing the storage batteries, motor-generator set and control panels. the Laval Steam Turbine Co. plant. Certain the final hobbing op- erations the manufacture speed-reduction gears cannot interrupted even subjected appreciable speed variation with- out affecting the accuracy the work. The reason for this that differences the momentum the work with relation that the cutting tool will tend produce variations the depth the cut. guard against power failure excessive voltage fluctuation, was decided install stand-by power source. The primary re- quirement was that the equipment have capacity supply the es- sential loads, ranging from kw. (75 100 amp. source; battery charge rates au- tomatically varying from trickle rate during stand-by periods more than normal rate neces- sary, following charge periods. General Electric engineers working with the Edison Storage Battery Co. designed automatic power-supply system consisting motor-generator set, battery and control equipment meet these requirements. The motor- generator consists one 15-hp., 230-volt motor and two 5-kw., 50- volt generators. The motor sup- plied the normal source during stand-by periods and the bat- tery during interruptions nor- mal source. The generators, each series with half (96 cells) the battery, regulate the voltage during both charge and discharge. The control panel provided with meters, undervoltage re- lay, disconnect contactors, and voltage regulators with their con- trol equipment. Two carbon-pile regulators vary the field current the generators through voltage control across the battery during charge and across the load during discharge. The regulators also perform the triple function charging the battery various rates from bucking the batter