The Iron Age 1942-12-10: Vol 150 Iss 24

wn-Lavino Philadelphia ative: Rogers, Bro Office: 208 LaSalle Stree PHOSPHATE Important Message All Turret Lathe Users There definite shortage Turret Lathe Tools equip machines for Defense Plant Corporation will authorize the return surplus materials. Present shortages cover practically all standard tools shown Warner Swasey Tool Catalog No. 38. Greatest shortages are the following items: Single Cutter Turners Tools (All Types) Kendall Square Building 238 Main St., Cambridge, Mass. Church and Franklin St. Cleveland 5701 Carnegie Avenue Dayton 436 Mutual Home Building 1308 Maccabees Building vital War Production. Multiple Turning Heads (All Types) Adjustable Turning Heads Angle Cutter Holders (All Types) Return for credit any new Warner Swasey tools. For in- structions write phone the nearest Warner Swasey office: Los Angeles 1118 Santa Avenue 818 Wells Building 324 Wisconsin Ave. Newark American Insurance Building Washington St. 6910 Market Street Upper Darby, Penna. 505 Medical Arts Building Syracuse 517 Erie Boulevard East Pittsburgh A | | ¥ RNE 4 * a @ a nue ling St. reet East DECEMBER 10, 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 J. |. BUTZNER S. H. BARMASEL Resident District Editors Washington Pittsburgh Washington Chicoa eland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP Milwaukee SANDERSON JOHN McCUNE Birmingham 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, Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit East 42nd St., New York obpinson Johnson, Market Research Mgr. Hayes, Production Manager. R. E. Baur, Typography and Layout. ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Price North America, South America and Possessions, $8: Foreign, $15 year. Single copy, 35 cents Cable Address Y." ° ° ° Owned and Published CHILTON COMPANY Editorial and Advertising Offices Chestnut and Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. U.S.A. Executive Offices OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE Vice-President Vice-President Vice-President This Week in... Editorial Incentive and the War Technical Articles Tool Life Increased Improved Plating Process Airplane Engine Power Recovered Test Smelting Iron Ores Electrically Time and Material Saved Making Lathes Accelerated and Retarded Phosphatizing Methods. Hints Correct Broach Low Tin and Free Tin Bronzes New Equipment Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Personals and Obituaries Machine Activity Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices Warehouse Prices Index Advertisers Copyright, 1942. Chilton Company 135 138 142 144 145 146 150 213 | a i ' | } | | } | | | | } | | } | | | | | —— War Production Complete System for Core Moulds for Magnesium and Aluminum Castings One the largest core baking and finishing systems ever conceived has been developed Mahon engineers for foremost builder aircraft engines. makes possible the pouring thousands castings each day. The section pictured but one four compact units. Each unit reality two complete systems—having twin ovens, twin cooling tunnels, twin batteries spray booths and twin drying ovens—through which the work from lines core-making machines, line, continuously travels series conveyor systems. Except for loading and unloading the conveyors, operation entirely automatic. Method transporting moulds, temperatures, ventilation, spray-painting moulds, all have been care- fully worked out insure moulds emerging from drying oven with- out breakage loss route. THE MAHON COMPANY DETROIT CHICAGO 40—THE IRON AGE, December 1942 Let Mahon Engineers Help You! The tremendous volume and speed-up war production presenting new problems the FINISHING war products. you have such problem let Mahon engineers help you. turers are finding thorough understanding modern finishing methods extremely invaluable meeting con- stantly increasing production schedules— with constantly decreasing manpower. Peci ment stems, ; it Metal Cleaning Machines, Proofing Machines, Air Supply Units, Foam Dust Othe, Unis Finish Incentive and the War America uses misuses its wide-spread initiative prosecute the war will determine our success failure. This undeniable but often overlooked truth was emphasized again and again the War Congress American Industry last week. “Initiative,” the words Howard Pew, president the Sun Oil Co., who spoke the Congress the subject, Initiative Will Win the “It not something that you can give man,” said Mr. Pew. cannot bought stores nor can acquired from books. Initiative attribute the spirit, springing out certain urges within mankind. finds its expression competition, and competition pos- sible only where there freedom choice and action. Where this denied, initiative dries and gives way inertia and inefficiency.” recognized that under the exigencies war production, indus- try must surrender some its initiative that the fullest possible power may brought bear attain certain objectives. Products must changed from peace war; certain non-essentials must curtailed; profits, wages and salaries must expect bear hard and unusual burden taxation supporting our tremendously increased, non-pro- ductive national financial burden. these ends, general objectives can DECEMBER 10, 1942 longer dictated private initiative. But unless and until make the fullest possible use private initiative help meet these ° necessarily dictated objectives, they will not met. Instead, they will ESTABLISHED 1855 choked death the weeds inefficiency sprouting from regimenting bureaucracy which limits attainment its own mediocracy. business, you want something accomplished, you find good man. Preferably one who knows more about his specialty than you. You point out him the general objectives that you seek have him attain. You give him the responsibility and the requisite authority and tell him it. And the good man that you thought was, goes and brings home the bacon. You not attempt make automaton him doing his thinking for him. government had set out apply this sound business principle defining objectives and making industry responsible for meeting them, giving industry the requisite authority so, would not have administrative army strap-hangers nearly rivaling size that our armed forces. The bigger grows, the less room will there for the exercise this precious ingredient success, initiative, the rest our great country. 4 if new production record brings smiles Inland’s veterans two wars. Steel Two Wars Set New Records Three veteran employees and the oldest mill Inland’s Indiana Harbor plant broke records 1917, and now are making new high marks for the company’s war production record book. This 24” structural, bar and universal plate mill was constructed 1901. One the veteran roll- ers, Dan Philp, started work for Inland 1909; Joe Carner added his skill 1910; and, Dan Fabian started the 24” mill 1912. Recently these steel veterans two wars stepped new all-time high—their production angles and plates for Liberty ships, and plates for Army truck parts. SHEETS STRIP PILING TIN PLATE RAILS BARS Be Street, Chicago TRACK ACCESSORIES Y The spirit these veterans typical all Inland men. Every Inland furnace and every Inland mill producing more steel than has ever made the past. Records individual mills often stand only few days before new high mark set. Maintenance men are doing their work engineers are crowding new construction the utmost—and every Inland ore freighter has broken its former record. Yes, Inland mills and men are doing everything possible give America steel for more ships, tanks, guns, all else needed win the war. PLATES FLOOR PLATE REINFORCING BARS STRUCTURALS Life Increased Improved Chromium Plating Process chromium plating small tools has been tried many times and has never proved entirely success- ful, method recently developed the engineering department the Crowell-Collier Publishing Co., Springfield, Ohio, has gone far overcoming the arguments against such process tool conservation. Months ago, when became difficult for this company procure high speed tools and cutters, Axel Lundbye, chief engineer the plant, began casting about for methods increasing tool life and conserving what little stocks high speed steel tools there were hand. After much experimenting, that chromium plating the cutting edges the tool best increased tool harden- ability and tool life, but there was considerable embrittling the tool because the hydrogen picked the tool face the plating bath. Various methods relieving this hydrogen embrittlement were tried but none were quite successful the use heated oil bath. This oil bath presumably releases the hydrogen which has been ab- sorbed along with the chromium, and doing decreases the brittleness the base material. The plating process used garden variety type, involving special techniques complicated plating baths. The tool plated first ground and then honed with fine stone give finer and smoother finish the cutting area and clean the steel preparation for the plating ap- plication. The cutting edge the chromium plating high speed steel tools and sub- sequently relieving inherent hydrogen embrittlement through the use special oil greater life and higher production rates can achieved with such tools. Drills, reamers, taps and form tools have been successfully plated, well lathe tools. ° ° THOMAS LLOYD Cleveland Editor, THe AGE tool then dipped into per cent hydrochloric acid bath for sec. and well rinsed cold water. This thoroughly cleans the cutting edge the tool. Use Chromium Salts Only The plating bath made oz. 99.75 per cent chromium trioxide, dissolved water, which 0.5 oz. concentrated sul- phuric acid added. The solution then made 128 oz. gal. The same proportions hold true for ance must made for the sul- phate content the chromium trioxide adding sulphuric acid the bath. The temperature the bath during operation held between 110 and 150 deg. F., and current densities range from 130 200 amp. per sq. ft., depending upon the material plated and the type plating required. When the chromium plating bath ready for use, the tool used the cathode and placed above the cutting edge. The anode preferably lead, although stain- less steel can used, and its size plated. the first step, the cur- rent reversed for short time from 200 400 amp. per sq. ft., again depending upon the material plated, making the tool the anode. the end this period, the current again reversed that the tool once more becomes the cathode, 130 200 amp. per sq. ft. When this has been done, giv- ing the tool flash plating, the cur- rent decreased immediately 120 180 amp. per sq. ft., and plat- ing proceeds for definite period time. The time limit quite variable, ranging from min. for each square inch steel sur- face exposed the plating bath, definite current density. This can best determined experi- ment. Oil Treatment After plating, the tool re- moved, rinsed well cold water, and dried immediately. The chro- mium deposit should semi-lus- trous blue-white, and distributed evenly over the tool. impor- tant that bead does not form the cutting edge the tool. Should this happen, the tool stripped the deposit and re- plated. After plating, rinsing, and dry- ing, the tool transferred oil bath which heated tem- perature about 350 deg. F., where remains for one hour. Then removed and allowed cool room temperature. This oil bath, believed, releases the hydrogen the deposit, and elim- inates hydrogen embrittlement THE IRON AGE, December 1942—43 } A con ° City the tool. After the tool has been oil-treated and cooled, the oil re- moved and the tool ready for use. has been found that avoid bead being formed the cutting edge tool that plated more heavily than the ness less than 0.0001 in., necessary raise the temperature the plating bath 150 deg. This slows down the rate deposit and makes the deposit smoother, permitting the chromium deposit built many more times the designated thickness. Offered License Free This process has proved highly satisfactory for use practically every type metal cutting tool, regularly increasing the tool life anywhere from 100 400 per cent, and permitting faster operation the tools. While patents have been applied for, the process has been released the company for the war’s duration for use govern- ment work, without royalties other charges. offer has been made plate sample tool for any company war work, and the results are satisfactory, the com- pany will given the specifications for the system and the engineers Crowell-Collier Publishing Co. will then act technical advisers, training personnel handle the process and heiping the set-up the equipment. The Springfield plant Crowell- Collier has reality developed into school save high-speed steel. Companies using the process have been sending men Springfield for periods three days learn how operate the system. date, more than 600 companies have been li- censed use the process, and close 100 companies have already in- stalled plating systems under the supervision the engineers Crowell-Collier Publishing Co. All Kinds Tools Plated Some the tools and parts which have given highly satisfac- tory service after plating the Lundbye process are: Drills, taps, reamers, forming tools, files, end mills, face mills, broaches, cut-out saws, punches and dies, thread gages, gear cutters, tool bits, gage blocks, piston rings, valve inserts and exhaust valves for internal combustion engines, dental burrs, and great variety other tools and parts subject wear, abrasion and corrosion. One recent job that was bit unusual but indicative the diversity application this process, was for Higgins, New Orleans. The Monel metal some pumps had replaced, because its scarcity, with tobin bronze, into which the pump packing cut quite severely. The bronze was plated the Lund- bye process, and now gives consid- erably better service than did the monel. Tests Gear Shaper Cutters Some results tests made large machine tool company the Middlewest indicated very great increase tool life for molybde- num high external grinding centers and molybdenum high speed steel cutters used Fellows gear shapers. the test, two new gear cutters were used, one being chromium plated depth 0.0001 in. and the other cutter remaining ters were identical, having specifi- cations follows: Diametral pitch, 8-10, pressure angle, deg.; num- ber teeth, 32; tooth depth, 0.225 in.; base diameter, 3.7551 in.; type, finishing cutter; cutter material, per cent molybdenum steel used the test was 8447, with Brinell hardness between 196 and 200. The chromium plated gear cutter was mounted Fellows 6-A type gear shaper and the machine speed was set 184 strokes per min., with 1080 strokes per revolution the cutter, and held constant throughout the test. The gear made two revolutions remove 0.040 0.045 in. stock over pins. This cutter finished gears teeth each, with tooth width 114 in. The teeth the first few gears appeared slightly rough, but became smoother more gears were finished. All gears showed satisfactorily Red Liner chart. The unplated cutter placed the same shaper and com- pleted the same test. Then, the plated cutter was re- mounted the gear shaper TABLE Metal Ground Off Sharpening Gear Shaper Cutters Number Teeth Cutter Width Cutter Width Metal Teeth per Performance Cutter Before Grind, In. Grind, Grind, Tooth Width Grind Ratio 0.8555 0.7605 0.095 1760 18.53 Plated 0.9035 0.8940 0.0095 5056 532.22 TABLE Performance Plated and Unplated Gear Shaper Cutters Cutter Material Condition Cut Plated 8447 8447 Plated 8447 Unplated 8447 44—THE IRON AGE, December 1942 Number Teeth Cut, Equivalent Performance Wide Ratio 5056 2.88 1760 Peeled 5740 2.67 2150 Peeled Tool After Experiment Red liner bad, tool not peeled but needed re-grinding Red liner good, tool could continue cutting i finish gears teeth each with 114 in. tooth width. The teeth were smooth and the gears checked well within the allowed limits the Red Liner. The cut- ter was removed and found good condition with the plating still intact. This cutter, this time, had cut 1500 teeth. The unplated cutter remounted the gear shaper and was started cutting the same type gear was completed the plated cutter. The twentieth gear finished, the fifth gear the second run, showed greater errors than allow- able when checked the master gear the Red Liner. The cutter was then removed and examination showed that one tooth had peeled back. The tool had cut total 1760, teeth before failure. The plated cutter was again mounted the shaper and was used cut gears teeth each. Upon examination after this run, was discovered that the plat- ing had chipped worn off the cutting edge the tool, but the cutter was still sharp enough use further, the metal the cutter had not peeled. All gears cut were within the limits allowed. The plated tool had, this point, cut total 3040 teeth in. width and was not too dull cut more. The cutter was again mounted, and gears teeth each, with tooth width in. were cut. chromium plating equipment can used the plating high speed steel tools and parts the Lund- bye process. Operators are trained three days Crowell-Collier engineers handle plating and treatment these tools. The in. width face this gear was equivalent 112 teeth the in. width. The gears were finished with two cuts the finishing cutter shaper speed 184 strokes per min., with 1280 strokes per revolution the cutter. The gears checked satis- factorily the Red Liner. Some the teeth appeared rough, but were good enough pass in- spection. The cutter, upon removal, was found slightly dull. Tabulating the results the test, the plated cutter had cut the equivalent 5056 teeth with tooth width in., while the unplated cutter had cut only 1760 teeth the same tooth width. Both tools were sent the grinding room for grinding. The amount metal ground off shown Table Plated Cutters Reversed Later, the unplated cutter was plated and the plated cutter was stripped its plating, and another series tests were made. These cutters were used finish cut gears with 114-in. teeth, and gears with teeth. Steel used these tests was having Brinell hard- ness 202 215. The same machine was used the pre- vious test and the speeds employed were 184 cutter strokes per min. with 1080 strokes per revolution the cutter. Standard feeds for this machine call for 1260 strokes per sec. The machine was running 14.3 per cent more feed than the stand- ard feeds specified. The gears made two revolutions remove 0.050 0.080 in. stock, over pins. The plated cutter, which the first test was the unplated cutter, was mounted. finished cutting the 80-tooth gears and the 69-tooth gears, without the Red, Liner showing teeth. The plated cutter this point had cut 4000 teeth, and 1449 teeth. This was equal 5740 teeth the tooth face width. this point the plated cutter was removed and found slightly dull. The unplated cutter, the one from which the plating had been stripped, was mounted the ma- chine and used until the Red Liner chart showed teeth rough. The job was finish the remaining 69-tooth gears which there were 29. For the first 23, the Red Liner gave smooth line, but the 24th gear gave rough red line. How- ever, the gear passed inspection. The chart the 26th gear was very rough and beyond the limits allowable error. The unplated cutter had cut 1794 teeth in. width, equivalent 2150 teeth THE IRON AGE, December !0, 1942—45 Ww rs er ° en n- e- in. width. Upon examining this cutter, was found that one tooth had peeled back slightly. Both tools were sent the grinding room for sharpening. The relative performance the two-gear cut- ters, both plated and unplated, correlated Table II. large Canadian manufacturer reported complete run ream- and hob. The reamer was cutting alloy steel the follow- ing analysis: Nickel, 3.00 per cent; chromium, 1.00 per cent; and car- bon, 0.35 per cent. The original production ran between and pieces per grind, but after plating, 646 pieces, increase over 2000 per cent, were completed be- fore grinding was necessary. The hob was used cutting gear SAE 4620 steel. The unplated hob cut pieces, while the plated hob finished pieces, increase about per cent tool life. manufacturer steel wool submitted steel shaving tools rigid test. The plated shaving tools ran average hr., min., before regrinding was neces- sary, while the check tools used the run stood for average hr., and min., before regrind- ing was necessary. The steel wool was reported have flown off the plated tools more smoothly than off the unplated tools and the plated tools could used very thin wire where such use could not made unplated tools the same number serrations. Armor Plate Drills manufacturer who converted his plant from peace-time produc- tion fabricating cast steel armor plate had similar success with the chromium plated tools. Several drills used drilling this cast armor steel were carefully checked against drills that had been use. One the plated drills produced 125 holes cast armor plate, and the drill did not yet require sharp- ening. screw machine products com- pany reports 12,000 pieces finished with plated combination straight and angular reamer, 4500 pieces with untreated reamer. plated form shaving tool used another manufacturer produced TABLE III Tests Lathe Tools Used mm. Shell Production Operations Completed Before Tool Ne. Condition Grind Plated 1290 Unplated 792 Plated 6633 Unplated 1520 Plated 2838 Unplated 1680 Plated 2838 1805 1360 1640 1860 1250 1380 1540 Grind 2nd Grind 3rd Grind | about 30,000 pieces against 3000 4000 pieces produced unplat- tools. large foundry the East had several types tools plated. One was 31/32-in. high speed steel gun boring cutter. The plated cut- ter operated 163 hr. surface speed ft. per min., and feed 0.012 in. The same cutter, un- plated, operated the same cut- ting speed and feed, averaged only hr. service before became too short for further use. vertical boring mill cutting tool, made Rex high-speed steel, was used boring armor plate. The tools were operated speed ft. per min., with 3/32-in. feed and depth cut. The plated tool completely rough machined the bottom rings two M-4 tank turrets, total hr. continual service. The standard tool, with plating, had ground twice complete one turret. midwest manufacturer elec- trical products had equally favor- able results. end mill cutter, used mill off bosses cast iron supporting frame piece, was | No. Average Number Operations 2nd Grind 3rd Grind Operations Completed Per Grind 1290 692 1484 742 6633 6633 4520 1507 2838 2838 4790 1597 2838 2838 4726 1575 TABLE Tests Lathe Tools Used 155 mm. Shell Production Operations Completed Before Tool Condition Bit Plated Unplated Bit Plated 318 215 Unplated Plated 782 998 Unplated 46—THE IRON AGE, December 10, 1942 150 4th Grind 5th Grind 6th Grind 7th Grind | Average Number Operations per Total Tool Grind 133 266 217 2716 872 291 | | | | 7 | | | | | | plated. This cutter machined 1100 pieces satisfactorily, while stand- ard high speed end mills used pre- viously machined only around 250 300 frames between grinds. Shell Forming Investigations large motor car manufacturer now produc- tion variety war products were also made. Tests were run are just few the tools that have been treated this process and are giving better service. Broaches, files, end mills, taps, reamers, milling cutters, piston rings, forming cutters, plastic and injection molds are among the tools and parts shown here. 155 and 20-mm. shells actual production, and investigators re- ported that Crowell-Collier 4 Publishing Co. has made definite contribution prolonging the life cutting tools.” production run 20-mm. shells, the results shown Table III were achieved, while pro- duction run 155-mm. shells, re- sults shown Table indicate the advantages the plated tools. Another shell maker reports in- creases tool life about 400 Tool Condition Molite Plated Molite* Molite* Molite*** Plated Molite Plated Molite Plated Molite Plated (new bit) | Steel round not heated Tool chipped feed, top only and test made Test No. Tool Bits 58.5 Tool dulled after 4-in. cutting length 58.5 Tool remained intact 58.5 Tool remained intact 99.0 Tool remained intact 68.5 Tool remained intact 134.5 Tool chipped and was set aside THE IRON AGE, December 10, 1942—47 ) | | | | | | TABLE Laboratory Test No. Cutting Tool Bits | Diameter Depth Cut Speed, Feed, In. Cut Length, Total Cutting In. Tool Condition In. Cut, In. Ft. per Min per Min. Time, Min. Remarks: Machine stopped after making above cut and tool was found chipped | Remarks: Machine and tool was found slightly chipped. Test continued slower speed Molite Plated 0.046 154.0 8.27 Remarks: Tool remained about the same condition, showing just slight wear. Remarks: Machine stalled, cutting tool showed point chipped off. Test began the following day the steel room temperature Steel heated about 125 dag. F., and cujting increased per cent firm tools for the nose test could held minimum. cutting. were used and boat tail and for the copper Furthermore, cutting speed was the tests, but each test employed band mm. shells. progressively increased until the steel different hardness. The cutting edge failed. Brinell hardness numbers these Laboratory Tests Two tests were made with each steels were: type tool bit. The unplated com- Pittsburgh Testing Laboratory, mercial tool bit that was used which does considerable research the first test chipped the start and testing materials and the cut. This tool was sharpened Diameter, In. Location Number processes, ran experiments three and used. the second test the commercial tool bits, which were unplated commercial tool bit identified its report Tool “A,” also chipped the end one TEST NO. tools, and Molite No. length cut. This bit was set rolled edge 229 per cent molybdenum), the aside and new one used the turned end 241 plated tools. The tests were made second test. Before certain cuts both types bits under were made, the steel round was TEST NO. nearly similar conditions was heated about 125 deg. F., keep 1 possible. coolant was used the temperature the steel about the tests that the time the the same for both tool bits while TABLE VII Performance Data Forming Tools Tool No. Type Tool Brand Condition No. Cuts Grooving form tool Plated 1020 Unplated 675 Plated and reground without removing plating 1065 Grooving form tool Trojan Plated 1220 Unplated 400 Plated and reground without removing plating 985 Rib form tool Rex Plated 925 Unplated 230 Plated and reground without removing plating 400 Rib form tool Trojan Plated 312 Unplated Plated and reground without removing plating 221 Grooving form tool Spartan Plated 312 Unplated Plated and reground without removing plating 221 48—THE IRON AGE, December 10, 1942 | | 7 q q Performance Plated and Unplated Twist Drills TABLE Vill Condition Plated Received Plated* 163 Unplated _is necessary when high speed drills are used. The tests run the Pittsburgh Testing Laboratory indicated that plating not only greatly increased the life the cutting tool, but also permitted faster machining opera- tions and heavier feeds. The actual results the tests are shown Tables and VI. The tests made various manu- facturers, along with those made the Pittsburgh Testing Labora- tory, indicate without doubt that the Lundbye chromium plating process for high-speed steel tools increases tool life. The chromium plate increases the hardness the tool bearing surfaces, the inherent chrome prevents gall- ing and building cuttings drillings, and the low coefficient Number Cuts Made After 1st Grind 2nd Grind 156 166 120 friction chromium reduces heat- ing the tool, with its consequent annealing effect the tool while operation. All these char- acteristics aid increasing both tool life and the speed produc- tion. has been found that even though the plating has been worn through tool, the remaining life the tool often higher than tool that was not plated. This probably accounted for the plat- ing process having chromizing action well plating action the tool. Furthermore, the plat- ing plain carbon steel tools has some instances permitted their substitution for high-speed tools. One large steel plant Canada stated that “it most apparent 3rd Grind Total No. Cuts 159 644 247 that the chromium surface materi- ally reduces the chip friction and although have not made such tests, are prepared say that the spindle torque also reduced. fully expect find that these tools are cutting with less horse- power than the standard high speed tools. This indicated the dif- ferent nature chips and improved finish the cut.” This steel plant made exhaustive examinations the performance these tools running plated tools against stand- ard tools machines exactly similar type the same production lines. The data shown Tables VII and VIII were accumulated this company. Airplane Engine Power Recovered Test connection with airplane en- gine testing the Melrose Park, plant Buick Motor Co., system power recovery used whereby large portion the fuel energy recovered electri- cal energy and pumped directly into the plant power lines. 1000- kva. synchronous alternator con- nected the engine under test means unique magnetic coupling. The alternator first used synchronous motor start the en- gine, then shut down. The mag- netic coupling rotor attached the alternator then held stationary air-operated brake. this position the magnetic coupling used absorption eddy cur- rent dynamometer. exciting the field the coupling, the engine loaded any desired value, all test speeds, and including the synchronous speed the alterna- tor. During this relatively short part the test, all power ab- sorbed the magnetic coupling and dissipated heat means water cooling. After completing this portion the test, the air brake released and the alternator again connected the power line. all engine propeller shaft speeds above the synchronous speed the alterna- tor, the magnetic coupling acts slip coupling transmit the engine power the alternator, which runs constant speed. this way the alternator and magnetic coupling deliver generated energy the power lines and absorb lesser amount energy, created the slip speed difference between the engine propeller shaft and the syn- chronous speed the alternator. With conventional type electric clutch, the torque the output shaft increases with the slip till point reached beyond which in- creased slip causes rapid decrease output torque. With the mag- netic coupling used here, increased slip also causes increased torque, but point reached which torque decreases with increased slip. result, the efficiency remarkably high. This character- istic also contributes stable speed control. This difference torque charac- teristic obtained through the use electronic d.c. supply for the excitation the magnetic coup- ling. This enables engine speed maintained constant value for any setting speed control potentiometer, and for any throttle opening. The engine will hold its predetermined speed and deliver any power the coupling, the capacity the engine the speed held, depending throttle setting chosen. THE IRON AGE, December 10, 1942—49 The plated drills were found holes production tolerances plus thus eliminating the regular subsequent operation reaming exact size. Reaming ence with iron furnaces and also upon experience gained from furnaces designed for the reduction nickel oxides Kris- tiansand, Norway, and plant Canada, Ivar Hole believed that for smelting pig iron the furnace profile must altered and the elec- trodes protected against pressure from the charge, since the charge this case had higher electrical conductivity. Mr. Hole also solved the problem the correct position the electrode the charge. His designs were eminently suc- cessful, and now possible use any kind reducing agent from the soft charcoal charred materials hard coke anthra- cite well any combinations those. Hole also provided the fur- nace with gas cleaning plant order utilize the furnace gas for héating purposes. Fig. shows schematic view the furnace appeared 1928, and Fig. shown front view one the six units type upon previous experi- IRON AGE, December 10, 1942 Spigerverk furnace that op- eration plant Southern Europe. The gas drawn out the furnace end and passes through cleaning plant located behind the furnace. The furnace charged through shafts, shown Fig. either from silos above from nearby bins means monorails con- veyors. Corrections the charge are made through the shafts when immediate correction desired through holes the arch. Because the low gas velocity the furnace, comparable large amount fine material may smelted without excessive dust loss. The temperature the outgoing gas low, averaging only 250 deg. (480 deg. F.) less, and the gas pressure also very low. Be- cause the low temperature under the arch, arch maintenance negli- gible. The gas sucked out the furnace and the pressure automati- cally regulated that only very small amount escapes through the ° ° ° 1G. 4—Schematic view the Tys- land-Hole furnace. Smelting Iron Ores shafts. Fig. can seen this small amount escaping gas burn- ing along the rim the charging trough. This desired indi- for the right operation the gas suction regulator. The arch provided with number holes covered fire clay cast iron plates, and the furnace thus made absolutely safe for excessive pres- sure. The furnace operates three- phase current and equipped with three electrodes each served single-phased transformers. The power factor somewhere between 0.85 and 0.95, usually 0.90 above. The furnace voltage whieh may high 190 volts adjustable under load either button control automatically. Ordinarily, how- ever, the furnace load adjusted mainly raising and lowering the electrodes, which mechani- cally and automatically regulated. Tapping The pig iron and slag are tapped through common tapping hole and are separated outside the furnace means syphon arrangement. The pig iron tapped into ladles molds, possibly into cast- ing machine, while the usually granulated. The furnace gas cleaned cyclone, scrubber electrical pre- cipitation. rule the gas suc- tion from the furnace automati- cally adjusted. Shutdowns are rarely necessary cleaning the gas channels and tapping are all car- ried out under load. “Slipping” the Electrodes always done under full power load. the heat concentrated the cen- ter the furnace crucible, away from the walls, and the intense heat zone surrounded only the ore charge and molten material (slag and iron), the heat losses are very small compared with that the standard blast furnace. These facts are mainly responsible for the unusual flexibility operation. \ Electrically The Tysland-Hole furnace, there- fore, can operated varying loads, and low per cent maximum load, without disturb- ances variation the iron anal- yses, power and electrode consump- tion. This flexibility possible operate with peak loads, and use surplus power when available. The should, therefore, considered de- sired power consumer. the low charge height and low gas amount, there are particular requirements physi- eal strength the raw materials, there the blast furnace charge, where the weight the burden makes necessary the use strong materials keep the charge open and permit passage the gases. The materials used are lump ores, sinter briquettes, which limestone added for formation the slag. The carbon used for ° ° 5—This the front view 7500-kva. Tysland- Hole furnace, which Southern Europe. ° ° ° ° HERMAN COWES Metallurgist, Det norske for Industri this, the conclusion two-part article, the author brings his survey electric smelting up-to-date with discussion the Tysland-Hole furnace, its construction, operation and competitive position with respect stand- ard blast furnaces. Operating data for five plants are herein presented. reduction usually mixture cokebreeze and coke the ratio coke and anthracite, well any charred products, can and are used. Practically the only carbon acting reducer the fixed contained the materials, leaving the volatiles less value. About 900 coke are necessary produce long ton pig iron, which less than one-half the amount coke used the stand- ard blast furnace. This im- portance decreases the amount objectionable impurities that enter the charge the coke ash, and affects the pig iron quality. The lower coke consumption con- sequently also decreases the con- sumption fluxing materials. Any kind pig iron may produced the Tysland-Hole fur- nace and silicon content a * THE IRON AGE, December ° per cent can easily obtained. The carbon content about 0.2 per cent depending silicon content. The conditions this furnace are very favorable for phur and low-sulphur pig iron can produced even when there are considerable amounts phur the charge. The furnace also produces excellent quality iron with coke the reduction ma- terial. Desulphurization high temperature the reduction zone which enables operation with Slag high basicity. The trapped slag taken care any the usual methods, but often granu- lated and utilized the production cement. The gas valuable by-product, and usually used for heating purposes, particularly the iron plant integrated with steel plant. still better utilization obtained, however, converting the gas chemical processes for organic synthesis. The gas may also used for sintering fine iron ores and for producing sponge iron. About 23,000 cu. ft. dry gas produced per ton pig iron. typical analysis the gas the 52—THE IRON AGE, December 10, 1942 Vol. Per Cent co. 2 Its heat value approximately 260 B.t.u. per cu. ft., thus repre- senting approximately 500 12,000 B.t.u. coal for each ton pig iron produced, which the gas state has higher value and effi- The power consumption per long ton pig iron 2200 2600 kw- hr., this representing ore normal iron content, and iron containing 0.50 2.5 per cent sili- con. higher silicon content re- quires somewhat higher power consumption. The electrode consumption normally for each ton pig iron. furnaces are equipped with the self- baking and continuous electrode, which was also developed Det norske Aktieselskab for Elektroke- misk Industri. This type elec- trode especially adapted for use electric ore smelting because its simplicity and economy oper- ation. Because its construction, against corrosion. stands against high densities and, being continuous electrode without joints, its maintenance 6—View furnace charging floor. small amount es- caping gas can seen burning along the rim the charg- ing trough. never ruption the operation. Because its low cost and high efficiency operation, the berg electrode has played im- portant role the development the electric processing ores general and especially iron ores for producing iron. Electric vs. Standard Blast Furnaces Actual competition between blast furnaces and electric furnaces does not exist since the conditions under which one the other more economical are rather sharply defined. The main adopted the price tween coke and electric power. Nature any one locality with both good coking coal and the means for de- veloping cheap hydro-electric power. Electric power generated from coal rule too expen- sive for electric ore smelting. brief thermal calculation the economic equilibrium between blast furnace and electric furnace for the same kind reducing agent shows, that this would coke equal about 1.8 times the price one kw-hr. However, this not the only deciding factor choosing the smelting process. Several other factors are taken into consideration, not all economical balance. Below are listed some the advantages offered the electric smelting process (1) High degree pendence physical conditions the raw materials, especially the reducing agent. This makes possible use cheap reducing material and produce pig iron localities where previously had imported, thus saving the freight expenses. (2) less than one-half the reducing agent contrasted with the blast furnace required, requirements flux, etc., are less and the amount produced slag lower. (3) consequence point (2) fewer undesirable impurities are contained the charge; therefore possible produce higher grade pig iron than could produced the blast furnace with the same materials. (4) The process offers excellent desulphurization, permitting the use raw materials which were formerly considered impossible. (5) Great flexibility exists operation iron specifications, and the possibility producing dif- ferent kinds pig iron short in- tervals. The silicon content the pig iron, variable within wide ranges, easily and quickly regu- lated changing the amper- age only, this also regulates the temperature the reduction zone. (6) furnaces are continuous and operate smoothly, they have high load factor and act favor- ably upon the power factor along the whole power line. Power producers should, therefore, favor furnaces, and favorable re] re} 7—This 12,000 kva. plant has briquetting plant for the raw material the foreground. power rate would thus expected. (7) Flexibility load makes possible take care peak and excess power. With possible the furnaces may considered “accumulators” electric power. This should enable consumer partly balance his power con- sumption operating with power cheaper rate, for example, week ends and holidays. may mentioned that already the practice one the larger steel plants, times power short- furnace only during week ends. has been proved within four hours after having been switched that the furnace operating with nor- mal load, despite having been with- out load during the week. Some other conditions favoring the electric furnace may men- tioned. One that erection cost per ton pig iron lower than for blast furnaces. Another, that the case blast furnaces, production cannot expected un- til the entire plant erected and this may take months. erected units and the production can start soon one unit completed months). The erection the entire plant made successively. case the condi- tions change during erection, this can discontinued any time. for the disadvantges, those have been briefly mentioned before. They include somewhat higher operating cost with respect man- power and dependence cheap electric power. There is, however, doubt that production costs can reduced considerably exten- sive mechanization. For countries with limited coal resources, electric pig iron produc- tion will utmost importance. will save their irreplaceable stock for products having sub- stitute for coal. Operating Data cent iron content for producing pig iron with silicon content 1.0 2.0 per cent, the approxi- mate production capacities the Tysland-Hole furnaces (load fac- tor 0.95) are: Transformer Capacity Daily pig iron produc- The slag weight will vary with the silica content the ore and the amount silicon desired the pig iron, the silicon re- duced from the slag. Thus, higher silicon content the pig iron will reduce the amount slag per ton iron. Although the amount slag can kept very low, certain quan- tity (about 700 per ton pig iron) usually desired for metal- lurgical reasons. There are technical matters obstructing the processing poor ores, only eco- nomical. The power consumption for the above mentioned ore 2400 2600 kw-hr, per long ton pig iron, depending the slag amount and the silicon content desired the pig iron. For every increase per cent silicon increase kw-hr, per ton pig iron may safely calculated. Electrode consumption amounts lb. per ton pig iron, depending some extent slag amount and silicon content the * THE IRON AGE, December A e }- e pig iron and kind reducing agent used. for coke consumption case cent ash, may calculated with 850 900 this country with its high labor wages and extensive mechani- zation, estimated the labor man-hour per ton pig iron will 2.5 1.5, depending the number and size furnace units, the higher figure applying when only one furnace operation. Two-thirds this for the furnace operation, the remainder for miscellaneous labor. Below are given some operating data from different plants: PLANT Tysland-Hole furnace with transformer capacity 12,000 kva. Ore: Foremost sintered hema- tite and magnetite concentrates. Pig iron per cent charged materials (except reducing agent), 54.3 per cent. Consumption Per ton pig iron Coke, 50% Coke 2380 kw-hr. 2474 Reducing agent, re- ccke with 11.5 per cent ash 860 Ib. 840 Electrodes 18.7 Ib. 20.7 Ib. Operating time per cent total for about six months 97.3 per cent. The average load was only per cent capacity operation had take advantage peak loads. Pig iron produced (High grade for special steel) 4.0 per cent above, 0.8 1.5, less than 0.025, less than 0.010. PLANT Tysland-Hole furnace with trans- former capacity 12,000 kva. Ore: Briquettes pyritic cal- cines, mainly from pulp plants. Pig iron per cent charged materials (except reducing agent), 46.3 per cent. 54—THE AGE, December 1942 Per Cent Reducing agent: Charcoal Coke Coke Breeze Average for months operating time: Power consumption 2525 kw-hr. per long ton pig iron Reducing agent (As coke 11.5 per cent Ash) Electrodes 21.5 Ib. Operating time per cent total per cent The average load was per cent capacity; full capacity could only used during week ends. Pig iron produced: High grade, about 4.0 per cent, 1.25 1.75. less than 0.028, less than 0.010. PLANT Tysland-Hole furnace with 7500 kva. capacity. Ore: Quartzose hematite composition 48.0 50.0, 28.0 24.0, Al.O, 3.0, and low. The coke had high ash con- tent, per cent, and 0.075, about 1.5 per cent. Due the high silica content the ore and ash content the coke, the slag amount was 2800 3000 lb. per ton pig iron, which more than three times the usual amount. Pig iron per cent materials (except reducing agent), per cent. The very smoothly with such large amount slag; power consumption was, course, high, about 3000 kw-hr. per ton pig iron. The pig iron analysis: about per cent, 1.25 2.00, less than 0.045, less than 0.030. The furnaces were operated dur- ing nine months the year, be- cause seasonal power shortage. PLANT Tysland-Hole furnace with 12,000 kva. capacity. Per Cent Coke: Ash, per cent Pig iron per cent materials (except reducing agent), per cent. Average per long ton pig iron for three months: Power consumption Coke 11.5 per cent ash 895 Electrodes 22.8 Average load per cent ca- pacity. Pig iron produced: above per cent, 2.0 2.5, 2.5 3.0, less than 0.55, less than 0.020. Below are mentioned the Tys- land-Hole furnaces built present, and their capacity. Transformer No. Capacity, Country Furnaces KVA. Norway 6500 Norway 9000 Norway Sweden 12000 Sweden 7500 Finland 12000 Italy 7500 Italy 12000 Italy 12000 Italy 12000 Japan 7500 The Tysland- Hole furnace has after only years reached high degree development has solved successfully the problem electric pig iron smelting with wide variety reducing agents, in- cluding coke. There reason believe that this furnace may built con- siderably larger units than hither- to. transformer capacity 25,000 kva are under de- sign. Consideration constantly being given the increase the furnace capacity order reduce the production costs and obtain the advantage otherwise offered plant was built the Norwegian government the time the invasion Norway. How far has pro- gressed not known. large units. what extent this shall succeed, time alone will show. rials 43.5 iron duce the the the pro- this how. the present war emergency, machine tool builders are faced with dilemma. Demand has skyrocketed unheard levels, but the need for steel and alloying elements for direct war production great that the machinery builders are hard pressed obtain sufficient materials meet the new production goals. Several months ago, use nickel steels for gears and shafts was ruled out, was the use nickel castings. general, the industry swing- ing over the National Emergency steels and revising its heat treat- ing practice take care these low alloy materials, but the Produc- tion Requirements Plan far has not envisioned even enough the substitute steels for quirements. Material shortages are the biggest problem facing the in- dustry today. Anticipating this situation, Gis- holt Machine Co., Madison, Wis., has developed line heavy duty saddle type turret lathes, Fig. much the requirements steel parts have been replaced high strength cast iron parts. These machines are now being produced new plant equipped with ma- chinery provided government funds. order achieve maximum pro- duction these new turret lathes minimum time, was neces- Sary design machine which could produced machine tool facilities then available readily obtainable. was also necessary plan the design-construction the turret lathe around materials Which are readily available the large quantities necessary. Time and Materials Saved Making Stripped Turret Lathes How Gisholt Machine Co. has built streamlined ver- sion heavy duty turret lathe which critical alloy steels have been largely eliminated and man-hours re- duced design simplification. The war machines are made two sizes present, designated the and the turret lathes. Capacities correspond the con- ventional and machine made Gisholt for the past several years.