The Iron Age 1942-12-17: Vol 150 Iss 25

DEC 1000 4.60 1.30 FOR RUSH JOB 6.55 1.00 3.00 When time short and accuracy vital, you 7.60 need the speed and precision Fairbanks Scales. Exercise your priority get the kind 9.00 weighing equipment that will serve you best now and the years come. Fairbanks-Morse scale engineers are ready aid you with many ingenious applications. Fairbanks, Morse Co., 600 Michigan Ave., Chicago, Illinois. 5.00 | 7 —® | Positive, Continuous Operation- Vital Now! THE IRON AGE, published every Thursday the CHILTON CO., More than years ago Eastern manufac- turer selected Cleveland Worm Gear Speed Reducers for the important drives through- out his large Mill, and now tells us:— “Cleveland Drives have given positive and continuous operation.” For over years— hours day 355 days year— not just one Cleveland but more than them have kept this manu- facturer’s machines steady production. Install Clevelands and you will keep your machines steady production too—with assurance continuous, trouble-free per- formance through many years come. Your Clevelands will never let you down! The Cleveland Worm Gear Company, 3252 East 80th Street, Cleveland, Ohio. Affiliate: The Farval Corporation, Centralized Systems Lubrication Canada: PEACOCK BROTHERS LIMITED WORM Philadelphia under act March Entered second class matter November 1932, the Post Office yearly North America and South America, Foreign $15. Vol. 150, No. 25. le fice DECEMBER 17, 1942 VOL. 150, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° Managing Editor, LIPPERT News Markets Editor, ROWAN Technical Editor, OLIVER Associate Editors Art Editor, WINTERS Editorial Assistants Resident District Editors Washington Pittsburgh Washington Chicago Cleveland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis BACON Seattle ° ° ° DIX, Manager, Reader Service Advertising 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 Ober, East 42nd New York W. J. Fitzgerald § 428 Park Bidg., Pittsburgh Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout. ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. lished every Thursday. Subscription North America, South America and Possessions, $8; Foreign, year. Single copy, cents Cable Address Y." Owned and Published CHILTON COMPANY Executive Editorial and Offices Advertising Offices Chestnut and Sts. East 42nd St. Philadelphia, Pa. New York, U.S.A, U.S.A. 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 The Hidden Hunger Technical Articles Core Sand Reclamation the Thermal Substitute for Lycopodium Parting Special Automotive Machine Converted War Work How Choose Electroplating Equipment Heating Metal Parts Induction Detecting Surface Flaws Welding Wrought Iron New Equipment: Material Handling Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Personals and Obituaries Machine Tool Activity Non-Ferrous Metals Scrap Markets .............. Iron and Steel Scrap Prices Critical Machine Tools Comparison Prices Finished Steel Prices Warehouse Prices Index Advertisers Copyright, 1942. by Chilton Company (Ine.) ° ° ° | Record-breaking service important Navy order, made possible Ryerson co- operation steel! “Without your assist- ance, could not have been accomplished,” writes the contractor—and again Ryerson teamwork scores. Cases like this—in which quick Ryerson steel-service has speeded war production —run into the thousands! While have not kept count, enough Ryerson customers are working war contracts firmly es- tablish Ryerson steel from stock vital part the war production machine. Hundreds plants war contracts are depending Ryerson for steel. impor- OFFICIAL U. S. NAVYP tant order here, too urgent wait mill production; few bars there; some strip few sheets somewhere else. multiplies into tremendous tonnage—all labeled it’s all going into tanks, planes, guns and ships beat the Axis! source pride the Ryerson or- ganization that its One Hundredth Year finds the direct line greatest service great deal satisfaction War Pro- duction Unit report: “Without your assist- ance could not have been accomplished.” JOSEPH RYERSON SON, INC. Chicago Milwaukee St. Cincinnati Detroit Cleveland Buffalo Boston Philadelphia Jersey City RYERSON | | DEC. 17, 1942 ESTABLISHED 1855 The Hidden Hunger week wrote about the need for preserving initiative even during the restrictions imposed national economy war. For without initiative wars can won, nor business made big from small beginning: are going preserve initiative, both during and after the war, must also take care its twin brother, incentive. For incentive and initiative hand hand and hard imagine the existence one without the other. During war, the great incentive should the universal desire everyone his part help his country win. Unfortunately, does not seem work out that way. The recent demands the railroad unions are typical the desire make more money taking precedence over the desire make more goods services. However, this not alone symp- tom attributable labor. Other sections our society have not been free from this natural desire. This hidden hunger for more can and should utilized incentive better war production. But should discriminatory and not horizontal application. People who more should get more. Not people who merely the same they have been doing, less. Unfortunately incentives for output have been frowned upon labor leaders general. Thus men and women who work are very largely paid for hours put and not for quantity quality work put out. Artificial classifications set establish wage differentials have largely taken the place individual incentives but they not permit the suit- able rewarding exceptional talent. fact, the system union stew- ardship actually penalizes prevents the exercise unusual ability and workers have been forced out work for doing too much. Pay based productivity would increase our war output least per cent and diminish the cost war production the taxpayers least half that amount. Labor whole would get much larger annual return compensation than now does, but would divided differently. Capable people would get larger share than they now and less capable not much. But that very distinction, working upon the hidden hunger for more that all would powerful incentive for everybody better. i | | i if | if | | | | iG | S. NAVY P | - q | | it y a = f ij ten hy << Dedicating Inland’s newest blast furnace. Left right, frontrow: Walsh, vice president; Mrs. Henry Straus, daughter the late Block, Inland founder; Wilfred Sykes, president; and, Ryerson, chairman the Inland Lights New Blast Furnace First Constructed Midwest Since Start War Molten pig iron—1,200 tons day—is now pouring from Inland’s newest blast furnace. Long before Pearl Harbor, Inland realized the coming need for greater sustained production pig iron and steel. Designs were made for new blast was started late 1941. Today, despite handicaps the labor and material shortages, this privately financed furnace has been completed record time and now producing pig iron. This new furnace takes its place the wp, i war program, not only augment pro- duction pig iron, but also safeguard Inland’s needed iron supply the event that other furnaces, long pressed capacity, must taken out service for needed repairs. Completion this new blast furnace the second major project undertaken and put into operation Inland since war began. Other projects including two additional blast furnaces for the Government all planned increase tonnage for America’s war effort rapidly nearing completion. ‘ 4 4 / / r aughter board, pro- vent ken ince ding the ease Core and Reclamation the thermal method ECLAMATION used core sand the thermal method production basis the aluminum foundry the Wright Aeronautical Corp.’s Ohio plant with highly suc- cessful results. This the first successful production unit installed this country for the reclamation used core sand the thermal method. contrast with the usual plant philosophy, which used core sand considered the light how filling for city dumps, the success the Wright reclamation unit has developed highly important source vital and somewhat scarce raw material labor and fuel cost between 35c. and 40c. ton, this cost being based fuel oil 40,000 Btu. 3c. gal. fuel oil are required per ton re- sand. The potential economies resting the efficient handling and recla- mation core sand have been over- looked many plants, due partly the fact that too often the true cost sand (including the disposal charge) not fully realized and due also the fact that skepti- cism has existed with respect the quality such réclaimed sand. Installations for the reclamation ° PHAIR Western District Editor, The lron Age ° ° The first successful production unit for the reclama- tion used core sand, the thermal method, now operation plant the Wright Aeronautical Corp., described this article. Various processing steps and. uses such reclaimed sand are discussed detail. ° used core sand the dry and the wet methods have been operation for some time several ferrous plants and have generally met with considerable success. For plants using wet shakeout, wet reclamation method logical, its efficiency being controlled the type core sand being worked and the binders used. Carbon Removal Possible Much the prejudice shown to- ward reclamation efforts has been based the belief that sufficient carbon could not removed from the sand make efficient reuse possible. While core sand can used many types cores without complete removal the film carbonaceous material that covers the grains after the sand has been used, (resulting from the action heat the binders) the resultant core usually rather brittle and requires the use larger quantities binding material. This latter ° factor, aside from tending lower permeability, also increases the cost the core. Experience the Wright unit indicates that the thermal method reclamation overcomes these ob- jections and provides reclaimed sand that can used safely place new sand for all applications the plant. The term “core sand” when used connection with the Wright re- clamation activities has reference dry sand mold for aluminum air- craft castings. The characteristics this material are quite similar the average internal core. Summed briefly, the Wright reclamation unit consists equip- ment which crushes the cores, re- moves gaggers, core rods, etc., then further granulates the core lumps, classifies them and passes them through kiln where they are sub- jected heat treatment 1400 1500 deg. This heat removes carbon and any organic material. THE IRON AGE, December 1942—43 4 3, — 3 | | * | Al | | i | | i iG if i | j i i 7 | | | | a ° | | ; | 4 sas Collector for fines, Kiln stack ‘Conveyor Conveyor , ory type crusher cloth screen breaker pulley Classifying screen used core sand reclaiming unit. The burned sand carried cooler and past dust exhauster which further classifies the sand. The sand then deposited bins, ready for reuse. Shortage Insurance The Wright installation was de- veloped through the combined ef- forts the foundry engineers Wright Aeronautical Corp. and the Link-Belt Co. Chicago, with the latter company building and instal- ling the unit. The reasons for the installation this equipment were several. The growth aluminum foundry ca- pacity was placing severe drain the sources the particular sand required for this type work. Thus the ability reclaim this sand was insurance against pos- sible shortage. Another factor was the belief that reclamation could made eco- nomically self-supporting. was felt that the cost reclaiming sand would less than the cost new sand delivered the plant. Ex- perience thus far has substantiated this belief. Still another factor was that this effort fitted with the company-wide efforts encour- age conservation raw materials. was logical that after developing effective methods reclaiming metal turnings, lubricating oil and cutting oils, attention should di- 2—First step granulating cores this breaker screen which passes lumps in. and smaller. Core wires, etc., work out the end the right. ane 44—THE IRON AGE, December 1942 rected towards the reclamation the next largest material, core sand. description various methods re- claiming core sand given “Modern Core Practices and Theories”, published the American Foundrymen’s Associa- tion, Chicago, beginning page 455. The unit currently operation the Wright aluminum foundry was designed primarily pilot model. Experience gained from this installation, the first its kind, will used the design additional units erected the company’s new aluminum and mag- nesium foundries. addition these two units, half-dozen additional installations are planned for other plants which also incor- porate certain modifications based the operation this pilot plant. However, these changes will largely matter refinement, for the principles reclamation used the Wright unit have proved practical and will still form the basis these additional installa- tions. Processing Method Fig. rough plan view, not scale, the equipment and the sand flow the Wright reclamation unit. drawn show the meth- processing, rather than the exact layout. The molds are knocked out over apron picking conveyor. the broken molds move this convey- or, laborers pick out chills, core rods, wires, etc., that were freed from the sand the shakeout. This con- veyor empties into rotary breaker (Fig. equipped with screen with in. holes. The tumbling ac- tion this screen further reduces the size the material in. smaller and passes the lumps through conveyor underneath. Screw 4 i | BELOW netic pulley removes core rods, etc., which slip past the screen shown Fig. RIGHT IG. 4—View the from the firing end, showing the oil burner. Sand enters the kiln the far end and works down the firing end. Large lumps, some which may held together core wires, etc., which cannot broken down the in. size, and core rods, gaggers, etc., freed during the breaker treat- ment, work out through the far end the screen, shown Fig. The lumps in. and under, after leaving this screen, are carried over magnetic pulley, which removes wires nails remaining the sand, and empties into elevator which raises the material bin. The type material caught this magnetic pulley shown Fig. From this bin, the sand passes through ring crusher which fur- ther granulates it. The next step screen which passes pieces smaller than mesh and throws off larger lumps into separate bin from which they may either discarded recirculated through the system. This material not being recircu- lated the present Wright unit, but will succeeding installa- tions. The material passing through this screen again run over mag- netic pulley which pulls out any iron oxides small ferrous par- ticles remaining the sand and the sand into large stor- age bin. Shakeout operations most foundries are erratic procedure and rarely represent truly contin- uous operations. the other hand, efficient and economical operation kiln this type reclamation unit requires that operated steadily and constantly hr. day. thus important that ample storage capacity available as- sure adequate, even flow the kiln, regardless the shakeout load. This the purpose the storage bin. From this bin mesh par- ticles, the sand fed screw con- veyor into the kiln rate tons hr. (new installations THE IRON AGE, December 4 it. under way will have greatly en- larged capacity). This kiln, Fig. standard depending upon the load, oil fired, and lined with wedge-shaped re- fractory brick. The slight inclina- tion the kiln, plus its revolving, serves move the sand slowly from the entrance end the discharge end where the oil burner located. the sand progresses down the length kiln oxidized at- mosphere, its temperature raised between 1400 and 1500 deg. This temperature has been found adequate burn off the carbon, while the same time not high cause fusion cracking the sand grains. Approximately min. required for the sand pass from one end the kiln the other, with about min. being required for complete trip through the entire unit, from the shakeout pit the stor- age bins. The revolving the kiln assures that every grain sand subjected the heat. This treat- ment the heart the unit and here that the objectionable car- bon and organic material are re- moved. Cooling From the kiln, the hot sand flows into cooling unit. This machine standard Link-Belt Roto-Louvre cooler, (Fig. 6), which has been found very effective job cooling addition permitting close control the rate cooling. This operation was originally in- tended only cool the sand but has been found that secondary car- bon removal takes place this unit, further improving the quality the sand. The sand heated between 1400 and 1500 deg. Fine water spray Discharge storage CROSS SECTION COOLER here about room here 150° 180 LONGITUDINAL VIEW COOLER 5—Construction cooling unit, where sand brought down safe handling temperature. the kiln, which brings the carbon the sand sufficient tempera- ture for oxidizing with the excess oxygen available with the standard combustion ratio. was found, however, that was not possible secure sufficient oxygen oxidize 6—Exit end cooler, showing duct which conveys reclaimed sand storage bins. Sample test can this photo shows free flowing quali- ties the sand after passing through the cooler. 46—THE IRON AGE, December 1942 PNG the sand completely and have the flame self-supporting. Therefore, when the sand, which discharged into the cooler while still the high temperature, comes contact with air room temperature, immediately absorbs large portion the oxygen from the air, causing so-called bleaching effect the cooler. Color the most convenient em- pirical method regulating the movement the sand through the kiln and the cooler. The operator strives obtain sand white possible from the discharge end the cooler and adjusts the flow, experience, achieve this end. The cooler fed with about 10,- 500 cu. ft. air per min. room temperature. This air reaches the sand through the longitudinal sec- tions the cooler, visible Fig. The arrangement the cooler such that air fed only into those channels that are directly under the load. Toward the discharge end the cooler, very fine water spray hits the sand, serving cool further. The volume this spray regu- lated thermocouple mounted the skin the cooling drum that the spray volume directly related the temperature the sand. This prevents the sand from leav- ing the cooler wet and not free- flowing. When the sand enters the cooler, its temperature about 1000 deg. and when leaves | ) quite dry and easy flowing and between 150 180 deg. The discharge end the cooler also fitted with exhausting unit which, addition removing the heated air, serves classify the sand further. controlling the velocity this exhaust, the amount fines removed from the sand can closely governed. Leaving the cooler, the reclaimed sand carried storage bins, ready for reintroduction into the core-making line. The fines are carried another bin for disposal. Some new units will equipped with arrangements for reintroduc- ing much these fines back into the sand necessary meet specifications. When the new high production units are operation, this reclaim- sand will used the Wright foundries for all purposes for which the new sand normally employed. This will necessitate changing the screens the core blowing ma- chine. For the present, reclaimed sand not available sufficient volume allow this change. Mixture Proportions Backing sand made from 100 per cent reclaimed material, while facing, reclaimed sand used the same proportions new sand, except that about per cent more cereal binder required. typical backing mixture used 1200 reclaimed sand 7.2 lb. Mogul binder pt. 4.3 pt. Hyten No. core oil per cent moisture emergency has been found possible use unburned re- claimed sand for backing, that is, sand that has not passed through the kiln. typical backing using unburned reclaim would fol- lows: 600 Ib. unburned reclaimed sand 600 Ib. Wedron No. sand 7.2 Mogul binder pt. pt. Hyten No. core oil per cent moisture When unburned reclaimed sand, used, the cores have tendency brittleness and the grains appear lack cohesion. some cases necessary dilute such sand substantially minimize this char- acteristic. has also been found necessary, when using unburned reclaimed sand, use large quan- tities binders. This reduces per- 7—Micrographs reclaimed core sand taken from various classifying screens. Top specimen from No. screen; bottom sample from No. screen. meability and raises the mix cost. The analysis the sand coming from the reclamation unit deter- mined largely the type sand going in. other words, when molds having relatively little facing sand but large proportion back- ing sand into the system, the analysis will differ from that the sand from molds which large amounts backing sand are circu- lated. Hence, there maximum per cent the anal- ysis the reclaimed sand from day day, but this variation not large enough require alteration mix proportions. comparison screen analysis ‘various types new and re- claimed sand given Table while Table gives comparison physical properties typical THE IRON AGE, December 1942—47 | | | | 4 4 7 4 q 4 mixes used Wright. Screen analyses are made every shift Wright, more frequently war- ranted. The amount carbon remaining this sand after passing through the unit about 0.5 per cent, ac- cording ignition tests. The microphotographs, Fig. show how thoroughly cleaned the reclaimed sand is. these photographs are studied closely, possible dif- ferentiate between the Wedron round grains and the angular Penn Glass grains. With recirculation, possible reclaim about per cent the sand going into the unit. Some loss unavoidable the form fines and dust, and there also loss conveying the sand through the various stages the process. small amount sand also remains adhered the core rods and wire. There appears limitation the number times sand may put through the reclamation sys- tem, provided that the temperature the kiln not permitted reach the point where cracking fusion takes place. Weak grains may broken down fines after time, but this the only direct loss grains the system. stands now, all the sand reclaimed the Wright foundry finds use; matter record, foundry officials assert that they could use larger amounts were available. The economics reclamation unit are largely determined the location the plant with respect the sand source. Thus plant located some distance from the sand source and consequently having heavy freight rate, would experi- ence higher saving from such TABLE Comparative Sand Analysis (AFA Standards) Reclaimed Sand Sample Sample Sand New Facing Core Blowing Sand Per Cent Retained 0.62 0.52 0.30 1.16 10.42 8.28 4.50 14.90 30.70 27.36 12.36 36.12 100 34.02 33.36 27.60 29.44 15.48 17.40 25.92 12.76 6.00 7.98 18.00 4.50 Through 2.58 4.84 11.50 1.26 99.82 99.74 100.18 100.14 Fines.... 8.58 12.82 29.50 5.76 Grain Fineness No. 78.85 81.17 107.26 67.19 TABLE Comparative Physical Properties Standards) Facing Sand Facing Sand Backing Sand Backing Sand Penn (50% Reclaim) Wedron No. 45) Wedron Penn Glass) Tensile, per sq. in. 165 178 124 112 Dry Permeability 131 120 Green Compression 1.0 0.95 1.6 1.1 Moisture, per cent 6.5 "Note: Above data are take: but are not averages. reclamation efforts than would plant located near its sand source. The fact that this system also acts assure supply the from samples from individual batches. They are typical, proper type sand these days scarcity also important fac- tor, but one not directly measurable dollars and cents. Substitute for Lycopodium Parting EVELOPMENT substi- tute for lycopodium parting for foundry use has been announced Delta Oil Products Co., Milwau- kee. Lycopodium was previously obtained from Poland and Russia, but the war shut off these sources. The new substitute developed Delta called “Partex” and made pulverizing hard, clean English walnut shells such manner produce dry, or- 48—THE IRON AGE, December 1942 ganic, powder that dusts freely. chemically treated have ap- proximately the same waterproof- ing characteristics the surface pattern and core boxes lyco- podium. Its structure, under the microscope reported very similar lycopodium. Partex said non-reactive with molten metals, free dusting and has uniform surface affinity for sand which eliminates building core boxes and patterns. special equipment required use this material and said eliminate the silicosis hazard pres- ent with certain other types parting compound. Field reports indicate that serves very efficient replacement for lycopo- dium. Its cost said sub- stantially less than mou Mid eith mac wor equi new job cost and cou era sta ing pre ate ist Special Production Machine Converted War Work rication sub-assemblies certain type heavy gun mount parts were awarded the Midland Steel Products Co., Cleve- land, the plant was faced with either long wait for expensive machine tools necessary start work the contracts retooling equipment hand. purchase new equipment for one part the job would have required machinery costing many thousands dollars, and the delivery such equipment could not have been made for sev- eral months. Since much the equipment Midland, like other plants, was in- stalled for special purposes, retool- ing existing machine tool equip- ment was the only means which production could started immedi- ately. While fill-in machine tool equipment, material handling equip- ment and stress relieving equip- ment had installed, the speed and ingenuity converting ex- isting equipment and actually start- ing production was considerable. The net result that the company not only went into production weeks ahead time, but today well ahead schedule and increasing its output weekly. One particular operation which existing equipment was adapted the war job was the drilling outrigger parts used the sub- assembly. The machines now use the drilling operations were especially designed and formerly used the fabrication rear axle housings and front end assemblies for automobiles. These machines had not been used since the curtail- ment automobile production and were stored the company’s in- ventory surplus equipment. order use this machinery, the gun mount sub-assembly was rede- signed the Army with the aid Midland engineers. This redesign greatly simplified the part that the machinery hand could used the job. Simplification design the part way decreases its use serviceability, but instead permits easier and quicker fabrication well facil- itates repair and maintenance. HEN contracts for the fab- Formerly Machined Axles The machines used drill 154 in. hinge pin holes the end the mount part sub-assemblies are two designs. One the ma- chines originally was constructed bore and ream rear axle hous- ings. Three spindles operated the housing drilling the gun mount parts, only one the three spindles used, the other two having been disman- tled. The part held place specially designed jig that the drilling and counterboring opera- the gun mount sub-assembly. These machines, which there are several use, can handle up- wards parts hour, good production rate machines even the latest design. This particular job only one the wartime proc- esses which have been installed Midland turning the plant en- tirely from peacetime products wartime production. THis machine, formerly used the manufacture rear axle housings for automobiles, was one the surplus pieces equipment utilized Midland Steel Products Co. war contracts. The two spindles that were dismantled for this job can seen, well the special fixture for holding the part. tions are performed simul- taneously from either end the machine. The other machine had double spindle head one end and single spindle head the other and was used finishing the front end as- semblies automobile frames, the work being done three faces. the new set-up, one the spindles left idle. The other spindle was already line with the spindle the other sliding head the ma- chine. With the special boring fix- ture, illustrated, hold the part place, this equipment being used drill and ream hinge pin hole Layouts for new assembly lines were developed and installed; con- veyors from the refrigerator lines, one Midland’s peace-time prod- ucts, had been piled the stor- age yard and were brought back service and utilized moving heavy parts; and training per- sonnel handle war production was accomplished quickly and ef- ficiently. the single job as- sembling the gun mount parts, machine tools have been adapted this special purpose are re- built units taken from the com- pany’s inventory obsolete and surplus equipment. THE IRON AGE, December 1942—49 something over 100 years old. has grown during the last years faster than all the pre- vious years its existence. has grown not only volume output but accuracy, precision opera- tion and quality product. During this quarter-century has changed sure the fundamentals electro- plating are not yet fully known (perhaps they never will be) but electroplating can now carried under planned conditions and with controlled operations. other words, electroplating can done such fashion achieve pre- determined end. Without question large part (how much impossible say) this advance may credited the chemist, the research worker, the academic man the industry. Without him, electroplating would still rule-of-thumb, guess-work process. And may said that the researcher and have received full credit for their achievements through the literature electroplating which has grown large proportions. The industry fully aware its debt the technical and scientific worker. But electroplating industry rests more than chemistry, metallurgy, physics and electricity. Indispensable these sciences are, electroplating (or for that matter, any other process manufacture) would helpless without the other support which has helped raise the industry its present high place—machinery and equipment. Indispensable the growth electroplating operations prac- tical manufacturing operation, elec- troplating equipment has also been responsible for some its longest strides forward. outstanding example that illustrates this fact the low-voltage direct current gen- erator, and what has done for the industry compared with the bat- tery. Strangely enough, the literature electroplating has devoted only minor part its space equip- ment. Libraries have been col- lected the chemistry and metal- lurgy electroplating; but com- paratively little its mechanical aspect—the equipment. For that reason, the purpose ( Courtesy U. 8. Galvanizing & Plating Equipment Corp. ) Single cylinder horizontal unit showing anodes place. 50—THE IRON AGE, December 1942 How Choose Electro this series articles describe this phase the industry. The ar- ticles will divided into groups based upon the type work han- and the operations performed, follows (listing them order operations performed metal products) Equipment for metal for plate: Grinding, polish- ing, sand blasting, tumbling, de- greasing, etc. Current suppliers and accessory instruments: Generators, rectifiers, rheostats, ammeters, voltmeters and ampere-hour meters. Tanks and containers Plating barrels Dipping baskets Conveyors semi-automatic and full automatic Dryers Equipment for final finishing: Polishing, buffing and burnishing. Each one these groups will discussed the following fashion: (1) General principles involved (2) Construction (3) Types available All these discussions will written from the point view the user, solve his problems and answer the questions which the manufacturer metal products (and for that matter any products) must ask. (1) What types equipment and material are available for work? (2) What will they for me? These articles will not pub- lished the order given above, but rather the light present day, war-time needs. For that reason, the first this series will de- voted plating barrels, which occupy such important place the mass production small parts for munitions and other war prod- ucts. Electroplating Barrels When small articles are plated, the problem making the necessary electrical contact presents difficulties. Often the work small that the labor wiring racking the pieces would unduly great. Sometimes they are such tu: tit plating Equipment shape—spherical, for instance— that wiring impossible. such cases, the rotating plating barrel the answer. The plating barrel appara- tus for depositing metallic coat- ing small articles large quan- tities. consists essentially revolving barrel-shaped container for the work, constructed that the current flows from the positive bus bars the anodes, through the solution, the work through the negative contacts, through the trunnions the bar- rel the negative bus bars; the load meanwhile being immersed the solution and kept the current circuit result the work al- ways touching some the various types contacts with which the plating barrels are provided, make connections the negative bus bars. Plating barrels are two main types: First the horizontal barrel with closed ends sides panels, which suspended tank that holds the solution; and second, the oblique tilted barrel with solid perforated walls and open top. Both types have their advantages and disad- vantages; they are made various materials and number different forms. The choice which type bar- rel use—the horizontal forated barrel the open end tilted type—will governed the size and shape the articles plated and the size the load. Per- forations the horizontal, tilting oblique barrel may small 1/64 in. slotted 1/32 in. round. general, the oblique units are used for “utility plating course would too small load plate economically the horizon- tal cylinders. However, larger ca- pacity units are available lb. and even higher, described later this article. Specific examples will illustrate the questions involved. plate load Ib. 150 Ib. screws, bolts, castings stampings in. ° ° ° ADOLPH BREGMAN Consulting Engineer, New York ° ° ° Electroplating equipment has been vital factor the development the metal finishing industry. This first article series analyzes high production machines, such plating barrels, which are indispensable the finishing war products. in. long, the horizontal barrel 100 lb. tacks, screws, buttons, oblique perforated wall barrel could used, proper size; or, nearer 100 than the hori- small tacks, screws, buttons, etc., the oblique solid wall barrel best. Many shops will find use for all types barrels. The tilted form, essential for very small articles, can course, used with those slightly larger size, but its plating efficiency lower, its ratio anode cathode surface low; hence may not economically feasible. Articles larger size, con- siderable weight should not han- dled any barrel, because some danger breakage the barrel; INGLE CYL- INDER unit, motor driven. ( Courtesy The UdyliteCo. ) and mainly, loss production defective plating, work marred abrasion heavy pieces. Horizontal Barrels The horizontal barrel consists cylindrical hexagonal (or some cases octagonal) hollow bar- rel, closed both ends, but with removable panel allow charging and discharging work, revolv- ing tank filled with solution the proper electrolyte. The bar- rel made with solid ends and per- forated side walls, the round per- forations varying size from 1/16 grid type may have horizontal slots between rectangular circular rod type staves. Interesting variations are shown, however, two addi- tional types cylinders that are THE IRON AGE, December 4 t i if ‘ | if i] i if if manufactured for large particu- larly heavy types work, and which are said better adapted than the standard panel type cyl- inder. One the laminated cyl- inder where the frame the bar- rel molded and the sections stack- one top the other form cylinder. The other rod type cylinder which designed espe- cially for heavy, rough cast parts. Both these cylinders allow unusual circulation through them. Simple the machine seems, principle, the proper design and construction plating barrel elementary matter. Ever since the first barrel was built (with can- vas panels) and later with wicker, celluloid, rubber covered steel and other types, the plating barrel has been one the most “tricky” ma- chines build, principally because had simple, and because AGE, December 17, 1942 ABOVE with molded-in copper conduc- tors, showing con- tact buttons set Bakelite blocks. (Courtesy Hanson-Van Winkle-Manning Co. ) ° ° ° RIGHT type cyl- inder for heavy work. ( Courtesy Crown Rheostat Supply Co. ) ° ° ° BELOW YLINDER and superstructure assembly; dan- gler contact. ( Courtesy Udylite Co.) faced with peculiar combina- tion chemical, electrical and mechanical conditions. always important use the largest permissible sized perfora- tions increase the current carry- ing capacity the unit. The best speed rotation, the obvious need for efficient contacts, the advan- tages and anodes used this equipment all have taken into consideration. The development present-day plating barrel design the result practical conditions and mate- rials available, well engineer- ing For example, the Inc., Newark, Private communica- tion. heads the original plating barrel cylinders were made out cypress and oak which were found lacking durability, necessitating the conversion equipment mahogany. The widest mahogany boards available were normally in. and these heads could cut from them most economically. Pecu- liarly, this figure was found both critical and satisfactory di- mension. The wider the head plating barrel, the further away from the anode are the pieces that are lying midway the barrel, and since the anodes must still fur- ther away from the outside the cylinder, prevent burning the work nearest them, the 14-in. diameter head was size. ind dit Further, since the surface area the work the plating barrel cylinder viewed from the cross-sec- tion that representing the parts lying along the chord and the seg- ment, the relationship distance load varies least from practical standpoint, with the use 14- in. diameter cylinder. For instance, assuming that the load were doubled cylinder that the height measured from the center the chord the center the segment were doubled, the surface area would increased approximately times (the length the cyl- inder being the same) and ad- dition, the length the cylinder were doubled, the surface area would approximately tripled. plating barrel cylinder, necessary use the flexure formula which includes moment inertia, section modulus, for transverse loads. Increasing the length the barrel, with cor- cause corresponding increase the moment and stress, and the loading causes the stress squared. Tripling the length the barrel which would automatically accommodate three times the load will increase the stress nine times when the barrel set motion. Torque involved and the stress directly proportional the torque applied. The consideration torque and Economic e Fifty-fourth Series Articles the Technical Aspects Metal Cleaning and Finishing also extreme importance pre- venting cylinder from twisting which would more destructive its construction than any other fac- tor. Since plating barrels must built with few retaining metal parts possible, the rigidity the cylinder depends upon correct de- sign and construction well the materials from which fabricated. The deflection inder, due excess loads, will also The barrels today are generally constructed Bakelite, hard rub- LEFT AMINATED cylinder with molded cross sec- tion stacked to- gether form the cylinder. (Courtesy Crown Rheostat & Supply Co.) BELOW der unit oper- ated without overhead ture. ( Courtesy The Lustre Co.) ber special composition. Which material best for all purposes for any specific purpose, still the subject much discussion. Rubber Bakelite will satisfactory for acid solutions—nickel, acid acid copper, etc. For alkaline solu- tions room temperature, with low caustic content, rubber, special com- position and Bakelite serve well. For alkaline solutions operated 150 deg., hard rubber special composition rubber recommended for cylinders moderate sizes. cylinders large diameter, there may tendency the rubber warp and become distorted, which would highly objectionable. One prominent manufacturer states that while rubber can used for almost anything, Bakelite less suitable for caustic solutions. The mechanical features the plating barrel, the drive mech- anism, handling equipment, etc., are designed use standard parts motors, gears, speed reducers, etc. Repre- sentative examples and their details are shown the accompanying il- lustrations. Sizes range from the small lot jeweler’s barrel, the large ca- pacity size, in. diameter and in. long. Large production installations are made mul- THE IRON AGE, December 1942—53 4 | | | = | | if | 4 2 oil i¢ = tiple-barrel units parallel, with over head trolley hoist and with hoppers for handling the cylinders and the work. The barrel most general use in. in. across the head in. in. long, and will hold from 150 work plated, depending upon the size and shape the articles. From practical standpoint may that the maximum load for the horizontal barrel will fill per cent the cubic contents depending upon the type contact used; the load, per cent. popular barrel has the current led out from the work and contacts through molded recessed copper conductors the ribs and live head. 54—THE IRON AGE, December 17, 1942 For heavy duty work, cylinders may 250 amp. per rib. Actually, how- ever, the current limited the electrical capacity the hub the center the spider the head the barrel, and few barrels carry more than 300 400 amp. al- though some installations for plat- ing bright zinc are using from 600 700 amp. Standard Bakelite cyl- inders have in. copper con- ductors the ribs, and the live head has in. copper star spider conductor. through these means that the current car- ried through the head, from the ribs, from the button contacts which are screwed into these ribs the inside the cylinder. LEFT ARREL installation units for nickel, brass, copper, tin and mium. ( Courtesy U. 8, Galvanizing &€ Plating Equipment Corp. ) BELOW IVE-CYLINDER vidual motor drive. ( Courtesy Munning 4 Munning, Ine.) The current passes through six ribs in. barrel and eight barrel, when the solution there are really only three ribs the solution one time. However, number installations, the barrel completely submerged. one heavy duty barrel, the rib in- serts are in. copper conduc- tors and the head inserts are in. The large sizes are necessitated the fact that the conductors are covered and would heat, expand and break the staves 250 amp. were carried through smaller con- ductor. With exposed conductors, smaller cross-section would sufficient carry 250 amp. the rubber cylinders, the rib insert av er worl will time erat par this tra con bus wit len th: ive — in. square bronze and the head insert in. bronze. Another factor which determines the current-carrying capacity the barrel is, course, the character the work. Heavy work with low proportion surface mass will have low current-carrying ca- pacity, due the lack surface contact between the pieces. Con- versely, light pieces with relatively large surfaces will have high cur- rent capacity. addition, the con- solution used, the temperature and the conductivity the solution will affect the cur- rent capacity the barrel, since some baths are more conductive than others. Other important factors are the depth which the cylinders are immersed the solution, the average anode-to-cylinder distance and the area anode surface the tank. The horizontal barrel primarily high production machine, capable taking substantial quantities work, current density which will turn out minimum time. addition, provides more even current distribution than the small oblique, solid-wall “utility” barrel, reason its ability expose larger surface areas the work the solution, and therefore type barrel plat- ing unit; cleaning, rins- ing plating, with work han- dled automatically. ( Courtesy Hanson- Van Winkle-Munning Co. ) general, turns out more uni- formly plated product. Ed. Note:—Next week the author con- cludes his analysis plating barrels examining oblique barrels, contacts, anodes, etc. Heating Metal Parts Induction heating parts tem- peratures about 500 deg. facilitate the insertion freeze- fit parts and for other similar op- erations now being accomplished parts means induction heat- ing. Several typical applications this process are described the American Car Foundry Co., New York, whose a.c.f. Berwick electric transformer heaters are used. One the smaller applications consisted heating Nitralloy bushings, measuring in. o.d. with in. wall thickness and length in., between 400 and 500 deg. This was accom- plished induction heating kva. With demand kva. the time was reduced min. sec. Two bushings were also heated si- multaneously min. sec. with kva. demand, using two coils. The particular type heater used this operation was 60-cycle low-voltage, low-temperature induc- tion heater. aircraft engine plant the same type transformer was used heat steel crankshaft in. long, having in. and tapered hole 334 in. i.d. maxinum. this application, illustrated, the heater was used raise the tem- perature the crankshaft about 400 deg. that expansion would permit the insertion free-fit bushing. The required heat was obtained with resulting expan- sion from 0.010 0.011 in. period about min. The same type transformer (heater) but with 150 kva. rating was used heating large axles preheat for welding. this in- a a TEMPERATURE 350 400 this aircraft crank- shaft about min. induction heating. The opera- tion required cause expansion suf- ficient permit the insertion freeze- fit bushings. stance the axles measured ft. in. long with diameter in. Heating this application was ob- tained resistance rather than induction and due the difficulty making contact with the polished shaft, air cylinders were employed pressing the contractors firmly against the ends the shaft. The required temperature about 500 deg. was reached from min. | | } THE IRON December 1942—55 ag typical Zyglo unit for in- specting small parts. ma- terial ment are within The curtained chamber the right the inspection station. Detecting Surface Flaws ON-destructive detection surface flaws well loaded parts important pro- duction aid plants producing vital war material. The method* detecting flaws most effective steel and other mag- netic parts, but has not been ap- plicable such non-magnetic parts aluminum, brass, magnesium, non-magnetic stainless steels, and such non-metallic materials bake- lite, ceramics, etc. The Zyglo meth- (U. Patent 2,259,400) has 12, 47, and March 19, 56, 1942. been developed the Corp. provide means for test- ing such non-magnetic materials. Surface flaws well loaded parts are great trouble raisers, particu- larly the load constantly vary- ing. For various well known rea- sons, the surface part more vulnerable than the interior and, consequently, small defects the surface are more apt cause trou- ble service than much larger defects the interior. Many surface defects can de- tected visually careful ob- server. But such inspection slow and less reliable than when the ob- server aided some process which will, effect, magnify the indication flaw. The X-Ray method excellent for large in- terior defects, but less definite smaller surface defects and, addition, costly for thorough job. Deep etching often effective but has the disadvantage de- stroying the surface. Magnetic powder inspection excellent 2—Typical indications vari- ous types cracks, the defect being indicated the fluorescent illumination. Left top indica- tion crack tungsten carbide tool bit; left bottom shows cracks molded bakelite; right top ser- vice failure crack cast aluminum duct; bottom right shows cracks and porosity molded ceramic part. may can! teri: arti cert has anc tra the ute int ces ret Non-Ferrous and Non-Magnetic magnetic materials but, course, cannot operate non-ferrous ma- terials. The Zyglo, fluorescent penetrant method, described this article the first really practical method indicating surface flaws non-ferrous materials with the certainty, speed and low cost neces- sary for production inspection. Operating Principles The principles operation this method are simple. First, the part coated with fluid which has the properties penetration and fluorescence and water wash- able. After application the pene- trant the part inspected dipping, spraying brushing, the parts are set aside for five min- utes hour more, depending upon the tightness the defect, allow the penetrant time work into the flaw, and also allow ex- cess penetrant drain off and recovered. After this setting period, all ex- cess washed off the Detection open surface flaws, such cracks and shrinkage, non-ferrous materials, including non-metal- lics, means the newly developed non-destructive fluorescent penetrant method described this article. surface the parts forced spray rinse warm cool water. After the parts are dried, absorbent developing powder applied the surface and the excess shaken off. This developing powder acts like blotter drawing the penetrant back out the flaws, and also re-