The Iron Age 1943-01-07: Vol 151 Iss 1

Pouring Electric Alloy Steel Flag, two flies MACHINE i 7 HEX. TURRET TOOL HOLDER POSITIVE STOP SET SCREW .030 RADIUS CUTTER SET SCREWS CUTTER HOLDER ADJUSTMENT SCREW HIS METHOD STEPPED PRODUCTION MM. SHELLS q machine tool operators deserve lot credit for applying individual ingenuity and resourcefulness speed war production. Such operator Chas. Marshall, setup man the Oliver Farm Equipment Co., South Bend, Ind. Operator Marshall developed tool for machin- ing radius mm. shells (see sketch). Because stop built right into the tool and locates from finished face the work piece, particular care need taken loading work slightly varying lengths into the spindle. Time was saved, accuracy improved, and production increased about 20%. with war bond his company. Many turret lathe operators have written us, tell- f ing how they have used the machines and tools hand best advantage. Many these ideas are passed along Blue Chips, shop bulletin now being mailed free the homes over 38,000 turret lathe operators. Are your operators this mailing list? Write Warner Swasey, Cleveland, Ohio. You CAN BETTER. FASTER. FOR LESS. WITH WARNER SWASEY | and man Ind. cates cular irded tell- along free LESS. JANUARY 1943 VOL. 151, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° ° ° Managing Editor, LIPPERT News Markets Editor, ROWAN Technical Editor OLIVER Associate Editors MacDONALD BARMASEL BENEDETTO Art Editor, WINTERS Editorial G. P. BUTTERS 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 Milwaukee Birmingha SANDERSON ROY MONDS Toronto, Ontario St. Louis BACON Seattle ° ° ° DIX, Manager Reader Service Advertising Robert Blair, Union Bldg., Cleveland Raymond Kay, 2420 Cheremoya Ave.. Los Angeles, Cal. Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, East 42nd St., New York obinson Fitzgerald 428 Park Bldg., Pittsburgh Johnson, Market Research Mor. B. H. Hayes, Production Manager. Baur, Typography and Layout. ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single copy, cents. ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE HARRY DUFFY CHARLES HEALE This Week in. Eighty-Eighth Annual Review Issue Editorial —By John Van Deventer ° ° Annual Review Features “1942” —The Year Reckoning DIVE BOMBER—Four Color Insert for Excellence ARMY-NAVY E—Four Color Pictorial Review the Year Steel—Training Gives Way War M-3 TANK—Four Color Insert Record Ore Movement—92,000,000 Tons Pig Iron Establishes New Record Scrap—1942 Trends and 1943 Plans Aircraft Developments 1942 TRAINING PLANES—Four Color Insert Air Warfare Comes Age LOADING BOMBS—Four Color Metallurgy War SHIP LAUNCHING—Four Color Insert Welding Given Tremendous Impetus War. BOAT—Four Color Insert Machine Tool Developments Non-Ferrous Developments and Plans ANTI-AIRCRAFT GUN—Four Color Insert Foundry Research Spurred War Detroit, The Phenix “Shipbuilding, Aircraft and Statistics the Metal Working Industry ° ° Features Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Copyright, 1943, by Chilton Company (Inc.) 101 103 110 113 118 123 126 133 136 140 143 148 154 159 160 162 166 170 174 176 178 181 ° JAMES q Here graphic evidence the character WELDED STEEL PLATE WORK that daily produced the Mahon organ- ization. This annealing furnace casing one twelve similar casings fab- ™ wet ricated for the same concern Manufacturers equipment es- war production are find- ing Mahon facilities inestim- able value where steel plate delivered Mahon less fabrication required com- than three month’s time plete their construction and “delivery promised” vital. Send your blueprints for quotations. They will receive our immediate attention. DETROIT CHICAGO 44—THE IRON AGE, January 1943 a & | q j 8 3 4 THE AGE JANUARY 1943 ° ° ESTABLISHED 1855 ° For Successful New Year years extending back beyond the memories most our read- ers, THE IRON AGE, each year, has published two “special” issues. One them, the Annual Review Number, has appeared the first week each year. The other, published the Fall, has marked the annual convention the American Society for Metals and has been known our “Metal Congress many years have these two particularly notable issues appeared, and appropriately have they fitted into the need and tempo our industry that they have lost the connotation “special issues” and have become recognized institutions. Not only have these issues received cordial welcome from our readers but they have grown progressively advertiser acceptance. And the normal times yesterday, being believers the spirit private enterprise and private profits, good publishers have endeavored increase that acceptance. respect advertising, for example, have heretofore and until now conducted special cam- paigns, personal selling well mail, the legitimate and believe laudable endeavor fully capitalize these exceptional oppor- tunities. have come the conviction that from now until the end our war emergency, these exceptionally large issues, which run five six hundred pages text and advertising are not order nor public interest. true that view the small circulation business and industrial publications compared with the general magazines, and view the valuable specialized information furnished them, one might find grounds for exception. One issue, for example, Life, Fortune Digest would probably account for more paper than would issues THE IRON AGE. However, that not the point. The point that make 1943 successful New Year, each and every one must his her part. For the duration, therefore, there will more special solicitations for these two issues. Their editorial services will continued usual, but far advertising concerned will “come what may.” a q 4 LL Better Steels Are Coming— from the Tests War Out today’s grueling war tests are coming better steels for tomorrow. Britain, Russia, North Africa, and the Far East equipment built American steel setting new performance and endurance records. But, have not yet come the end, for world-wide battle tests are pointing the way new requirements that are being met the laboratories and the steel mills America. Inland actively taking its place this new phase the steel age. Before World War Inland gave industry such valuable steel mill products as: strength Hi-Steel; fast machining Ledloy; finer cold reduced tin plate; etc. Today, with greatly enlarged research facilities and the valuable experience exacting wartime produc- tion, Inland looking forward meeting the steel needs America peace. \ \ BB A ZA N ttt, LEE w \ | | k x as j 4 j — : \ \ 3 q | nee * | disconcerting string complex confusions was somehow parlayed into rather creditable industrial per- formance. But, 1943 brings batch new and untried that will test the native labor, management and politician. LIPPERT Managing Editor, THE IRON AGE HEN viewed broad pan- orama, the net results the country’s greatest in- dustrial convulsion add fairly neat achievement 1942. All this despite the frightening imperfections detail; whole dark pile political mockeries; early “boners” ordnance and air- craft; persistent dilutions the war effort with self-interest certain industrialists and some labor and farmer spokesmen; and newspapers with their anarchy frothy buncombe and agony art- less floundering will-o’-the-wisps. Somehow, some- way, inchoate ground swell imperfect and undramatic individ- ual effort complemented indus- trial desire hammer out com- pact and solid piece production —all this, partly the result and partly spite the con- geries bickering personalities and ineptitudes OPM-WPB, some unrecordable manner into industrial performance considerably better than expecta- tions. Some $52,500,000,000 was poured into industry was converted, concentrated and stuffed into the pinching corset all-out war pro- duction. Aircraft assembly 49,- 000 planes (trainer percentage was fairly high) fell somewhat behind expectations, did also tank and self-propelled artillery output 48—THE IRON AGE, January 1943 32,000 units (light tanks predomi- nating), while 17,000 anti-aircraft guns and 600 per cent increase ammunition came closer expecta- tions, and the very capably planned merchant shipbuilding program jumped fivefold 8,200,000 dead- weight tons. Finished steel output lifted 1,500,000 tons over 1941 with alloy showing 400 per cent gain; magnesium output doubled and re- doubled many times, with the new Basic Magnesium plant alone rated times total 1941 production aluminum spurted almost 100 per cent above 1941; vast and ambi- tious production and technical schemes matured copper, nickel, tin, molybdenum, vanadium, zinc, chromium, tungsten and such were the preliminary results that pres- sure certain elements shifted from the hopeless the uncritical categories. For this year 1943, the inten- sity war production will screwed another 100 per cent, total expenditures the neighborhood $90,000,000,000, and only then will there that desirable four-to-one smashing su- periority over the Axis the flow materiel. has became rather fashionable late eye manpower the critical factor involved the in- spiring production goals 1943. This rather significant that materials, and times the almost chaotic distribution materials, 1942 was the curse every phase war production. There nothing gained reviewing the depressing confusion and pro- gressive deterioration the prior- ity system its shotgun wedding with the Production Requirements Pian. Both these are horizontal materials allocation schemes with compounding complexities, admin- cracy containing excessively high percentage inefficient and indifferent governmental em- ployees, spilling through all the hallways Washington, which was superimposed ever-shifting heterogeneous supervisory mixture industrial riff-raff and highly capable individuals working under practically intolerable conditions, both mentally and physically. the top, Mr. Nelson, albeit ex- cellent gentleman, was apparently inclined talk overlong about being over the hump, fill his string pipes each morning rather than unburden his terribly top-heavy organization obvious non-producers and misfits, con- tinually back away from rather than embrace his opportunity permit nibbling his authority the armed forces, and suffer at- tacks men from industry who had practically shanghaied Washington. The purge and rebirth WPB, long anticipated and cynically awaited, apparently com- pleted. Strong men brought into WPB—men, who like Jeffers actually fire incompetents; from the all-potent Army-Navy Munitions Board, liaison with the military | | t | and administer materials with un- emotional efficiency; Wilson, who organized aircraft production, and now controls all production; and number others down the line tested ability and vision. And, while the base the pyramid still hundreds useless workers that are parody talk labor shortage, WPB general out- growing the acne and elbowing self-conceit adolescence, and ap- pears settling down the pompous mediocrity middle life. Apparently perfection not de- sired that great production en- gineer Henry Kaiser has not been placed the elbow Donald Nel- son, the Tolan house committee suggested. course, even more promising than the improved personnel the materials set-up the new Con- trolled Materials Plan, CMP, which vertical allotment sys- tem scheduled for full operation July for steel, copper and alu- minum. Under it, prime contrac- tors will submit breakdown .and quirements for approved end-prod- ucts which they are working. These Bills will pass through agencies (Army, Navy, Aircraft, Lend-Lease, etc.) the WPB Requirements Committee. When requirements are brought into bal- ance, allotment numbers will dis- tributed prime contractors, and from them sub-contractors and suppliers. These allotment num- bers will constitute right re- ceive delivery. CMP apparently was conceived and nurtured the Army-Navy Munitions Board Batcheller and Eberstadt, patterned basically the English and German systems with few embellishments and ad- aptations the industrial mores the First, was visual- ized only for steel, and was un- veiled the premature fated so-called Reese Taylor plan. Only later, with Batcheller and Eberstadt WPB, has Nelson backed this new scheme. The great potential danger CMP that has been expanded from steel alone cover copper and aluminum also, and expecta- tions are that even other materials will eventually included. ac- commodate each new material, cer- tain modifications have made the plan, and more serious that over-all control shifts less efficient top supervisory group agency. Possible inefficiency inept over-all supervision may again bog down the underlying units, and short time the initial Division Steel Industry Operators, for instance, may weakened such over-all au- thority, regardless any personal promises non-interference. This would seem rather unneces- sary, there apparently valid reason that prevents single- head integrated administration these key industries whose maxi- mum efficiency essential win- ning the war. much for the broad outline production, past and present. Weav- ing throughout the fabric dis- turbing labor problem, both nu- merically number potent metallurgical and technological shifts, both practical and nebulous; rather futile argu- ments about quality armament; much loose talk about the coming light metal-steel fight for suprem- acy; and the underlying uneasiness all minds regarding post-war adjustments, the bulk people quietly floundering between the ex- treme one hand reactionaries extolling the joys Adam Smith unfettered, opposite extreme the cold mathematical planning the worshipers econometrics who foresee the future the terms world made perfect technology and the applied social sciences. Steel, Child! Some future actuary, morbidly humorous, may designate 1942 the year stomach ulcers with particularly high incidence the steel industry. Articulated was with every phase the rear- mament effort, steel, the past months, was Friday’s least favored child—a woeful football for every harpy-brained extremist maul. Those frigidly tranquil individuals admitting problems ding- donged counterpoint the deliri- ous refrain others deploring gaunt war industry famished for want ferrous metals. Neither fierce extreme had basis fact. There was not enough steel 1942. The shortage was, unfortu- nately, considerably emphasized maldistribution via inept and pro- gressive complexities the prior- ity system, spotty stock accumu- non-essential and certain un- = —® necessary and over-accelerated con- struction projects. Even so, without those drains there still would not have been enough steel for all war demands. But, lest those “I-told- you-so” individuals should mock, should emphasized that without 10,000,000-ton raw steel export load, the domestic steel and alloy position 1942 would have been relatively peanut proportions. Actually, some 63,700,000 tons hot rolled steel all types (see Tables and II) were produced 1942, broken down from about 86,300,000 tons ingots. With the most sanguine optimists last Janu- ary predicting 83-84 million tons ingots, 1942’s performance rep- resented fair amount relent- less mill pressure and clever techni- cal improvising, the seldom appre- ciated complications which are described detail page 85. regards metallics support this record output, pig iron production about 60,000,000 tons likewise exceeded expectations (details page 93), and the startling return 16,000,000 tons purchased scrap the mills (details page 96) dealers and brokers was undramatic and unappreciated vic- tory—a performance marred months calm indifference and little ignorance WPB, shattered scrap drive sponsored newspa- pers, with professional scrap men being belatedly sucked into maelstrom price, segregation and delivery misunderstandings. The details the blotting record 63,700,000 tons steel 1942 has been attended consid- erable mystery and little misin- formed debate. However, the data Tables and show relatively normal distribution patterns, both regards products and consuming industries, with several dramatic THE IRON AGE, January 1943—49 | | f | 1941 1942 PRODUCTION. PRODUCTION. 62,324,187 63,748,056 TONS TONS SHEETS AND STRIP SHEETS 15.4% AND STRIP 25.9% BARS 16.5% PLATES 18.8% SHAPES 8.9% TIN PLATE 5.6% WIRE 7.4% PIPE 7.8% ALL OTHER 19.6% BARS 17.6% PLATES 9.9% SHAPES 9.2% TIN PLATE 7.7% WIRE 8.5% PIPE 10.6% ALL OTHER 10.6% Shift product participation total steel consumed during com- pared with 1941. Note that the spectacular lift plate output came sharp inroad into sheet-strip production, with all other products contributing lesser degree. See graph above and Table below for details. Red indi- cates percentage decrease from 1941 1942, and black represents increase. exceptions. The breakdown pro- duction product, Table and Fig. shows minor declines for most products, even for bars and pipe which support the shell and bomb programs, with sharp and rather ominous constriction tin plate deliveries. terrific bite was taken sheet and strip pro- duction through killing off automobile assembly. building and construction were primarily responsible for lifting plate output unprecedented level. About the same story told Table and Fig. which trace steel into consuming outlets. Here, steel going into construction just little above 1941 consumption; agriculture, railroads, containers, machinery and oil and gas, all participated lesser degree, whereas the automobile industry accounted for less than per cent the total. The two multiplied drains steel were shipbuilding and export, each accounting for over per cent the total steel. Enlightening last year’s dis- tributions are, however, more per- tinent the probable allocation some 69,000,000 tons rolled steel this crucial year 1943. Cer- tainly, shipbuilding lift 100 per cent more, account- ing for some 20,000,000 tons steel; export will likely some 1,000,000 tons higher the neigh- borhood 11,000,000 tons; the automotive-aircraft classification should rise and railroads will likely receive less steel. Containers should but probably won’t lift civilian and military feeding main- tained and Lend-Lease and for- eign rehabilitation are be- the talking stage; agriculture will likely show little change; ma- chinery will probably participate lesser extent, whereas pressing, TABLE Production and Steel, Product (1929, 1935-1942) (In Net Tons and Per Cent Total) Skelp and Sheeis Seamless Tube Plates and Strip Shapes Bars Billets Wire Rods 1929... 6,624,798 18.8 11.6 5,487,339 11.9 1936... 2,829,950 7.5 11,447,319 30.2 8.6 18.0 4,225,272 11.2 3,357,626 8.9 1937. 3,632,438 8.8 29.2 8.9 6,755,012 16.4 4,705,954 11.4 3,370,405 8.2 1938 1,919,835 8.1 29.5 2,082,685 8.8 3,484,923 14.8 2,882,471 12.2 2,361,630 10.0 1939 3,101,981 7.9 30.4 3,358,985 8.6 15.7 11.1 3,680,297 9.4 1940... 4,323,408 28.4 4,232,346 16.4 5,029,966 10.5 4,351,848 9.1 1941... 6,199,575 9.9 25.9 9.2 17.6 10.6 1942... 11,974,023 8.9 10,474,736 16.5 4,950,405 4,550,397 7.4 TE: Data for 1929, 1935-1941 from American Iron and Steel Institute; 1942 figures are estimated the Rails, Black Plate Wheels, Ties All Total for Tinning Splice Plates Other Production Total Tons Total Tons Net Tons 2,307,462 8.6 1,193,199 4.4 905,037 45,232 7.8 30,456 37,857,544 3,308,576 8.0 2,320,896 5.6 1,391,732 41,178,366 2,191,905 993,684 4.2 703,069 3,468,358 8.9 1,994,796 5.1 1,117,384 3,625,551 6.0 3,028,795 4,818,922 7.7 2,961,999 4.8 62,324,187 3,585,152 5.6 3,561,937 9,137,040 63,748,056 50—THE IRON AGE, January 1943 | | forming and stamping will perhaps lift sharply the shift steel PRODUCTION. shell cases approximates the fancy promises being made. Product- TONS TONS wise, the sharp increase over 1942 will plates, with more mod- erate advances sheet, strip and tin plate. The 8,100,000 ton monthly rate ingot production reached the completion the expansion program 1943 will produce monthly approximately 5,780,000 tons finished products. The dis- tribution these products and the raw materials required make them are shown the flow dia- gram pages and 53. par- ticular significance the large in- crease made 1942 and com- pleted 1943 for alloy steel pro- duction which essential the production shot, armor plate and machine tools. The larger part the alloy steel production the open hearth, but electric fur- nace capacity being expanded rapidly that the middle 1943 the capacity should total the neighborhood 6,153,000 tons an- nually. The total production alloy steel 1943 will probably range over 1,230,000 tons monthly. Examining the probabilities involve sharp reduc- tions steel going into construc- tion and machinery and widespread but temporary constriction ord- nance items such shells, many observer has become enamored freely prophesy comfortable steel surplus 1943. What titillant that is! But, view the greatly expanded demands shipbuilding and export, with added load from the aircraft panded ordnance items such CONSTRUCTION 16.4% CONSTRUCTION 16.8% AUTOMOTIVE AND AIRCRAFT 5.6% CONTAINERS 6.3% 16.3% MACHINERY 4.5% AUTOMOTIVE 15.8% AIRCRAFT 0.9% RAILROADS 9.6% CONTAINERS 7.4% SHIPBUILDING 4.7% MACHINERY 5.4% OIL, GAS 4.7% AGRICULTURE 2.7% EXPORTS 9.7% EXPORTS 16.9% ALL OTHER 22.3% Shipbuilding and exports expanded steadily 1942, compared with 1941 percentage total tonnage basis, there being complementary sweat- ing down automotive participation. Other consuming outlets were invaded minor degree, detailed the graph above and Table below. TABLE Steel Distribution Consuming Industries (1929, 1937 1942) 1929 1938 1940 1941 1942 Construction........... 8,643,040 18.8 6,037,920 14.7 4,398,240 18.7 6,935,889 10,714,977 168 Furniture, furnishings... 1.5 1,494,080 3.6 3.7 3.0 (b) (b) (b) Oil, gas, 4.117,120 8.9 7.4 1,841,599 4.7 1,900,286 4.7 1,585,969 Pressing, form., stamp.. (c) 659,864 1.7 3,677,127 5.9 17.7 4,686,080 11.4 1,443,680 6.1 3,250,022 4,019,219 8.3 6,983,122 9.6 4,400,444 7.0 6.4 1,752,800 7.4 2,594,700 6.7 8,098,874 16.6 6,045,446 9.7 10.800.000 16.9 All 7,178,666 15.6 7,329,716 17.8 11,155,458 28.7 9,365,834 19.1 10,470,462 16.8 11,406,271 45,997,746 100% 41,178,356 100% 23,568,951 100% 100% 100% 63,748,066 NOTE: Distribution 1929 1938 Worthing, based data from The Age; 1939 1941 from The Iron Age, various Government reports, and estimates, with jobber tonnage distributed and other alterations made the author accord- ing the technique devised Worthing; 1942 data are estimates the author. (In Net Tons and Per Cent Total) Negligibie, not available and All Other. Included Pressing, Forming, Stamping. partly under Furniture and Furnishings and partly under All Other. THE IRON AGE, January n )- g OIL. GAS 2.5% | ill ALL OTHER 23.6% he in- ire ction Tons 7,748 0,298 7,544 8,356 8,591 0,369 4,187 8,056 | tanks, guns, shells, bombs, and steel shell cases, proselytize steel surplus the author hunk wishful thinking that could well tucked into cubby-hole alongside visions cowed Axis year’s end. Any production 97,000,000 more tons steel ingots 1943 will involve unprecedented pres- sure available metallics. There- fore, the problems involved sup- plying adequate iron ore, pig iron, scrap and so-called sponge iron, are first-rate importance. regards iron ore, over 2,000,- 000 tons more were brought down 1942 1942 than had been anticipated, and currently there about 8,000,- 000 tons more lower lake docks than similar period year ago. And, for the 100,000,000 tons scheduled come down from Su- perior the 1943 season, new boats seem assure complete suc- cess without dependence any unconventional practice winter rail movement (see page for details). factor tending ease supplement the ore supply will the installation consider- able sintering capacity during the year, perhaps even approaching average per cent ore require- ments, ratio that only Republic currently has completed under- way. There are really enormous flue dust scattered around various plants, several instances the order many million tons. Sintering equip- ment would tend absorb these inventories into production. Although ore receives the bulk attention, relatively third position among the factors influ- encing pig iron supply 1943; coking coal will the second most serious problem, not that under- ground reserves are not plentiful indeed, but the physical job get- 1943 Flow Chart Steel Production Productive Capacity With Raw Materials Required Completion Expansion Program During 1943. Distribution Finished Steel for the Year Shown the Right. (All Figures Net UMESTONE PIG IRON: 34,716,000 (BLAST FURNACE ONLY) TOTAL PRODUCTION 6,721,000 MERCHANT IRON AVAILABLE FOR 6,153,000 IRON ORE COKE MATERIALS REQUIRED FOR O. H., 57.968.000 BESS.. AND ELECTRIC STEEL: COAL PIG IRON 61,579,000 RECIRCUL'G SCRAP 27,192,000 82,611,000 RAW PURCHASED SCRAP | 4,386,000 216,615,000 8,911,000 8,137,000 84,241,000 STEEL 97,115,000 HEARTH BESSEMER CONVERTER BLOOMING SOAKING OPEN-HEARTH FURNACE BLAST- FURNACE STEEL ALLOY AND STEEL CASTINGS ROLLS ALLOYS, ETC. FURNACE STAINLESS STEEL 52—THE IRON AGE, January 1943 LIMESTONE ting the greatly increased tonnages out demands that traffic every little entry pile thorough- fare density; and, the tightest squeeze 1943 will likely coking facilities, both by-product and bee-hive. While the limited reserves very high grade ore the Supe- rior region one the oldest and best documented facts the steel industry, quite bit excitement developed late 1942 regarding the inevitable liquidation the reserves. Not having enough war worries already, many readers various articles Saturday Eve- POSSIBLE DISTRIBUTION CAPACITY SEMI-FINISHED MATELY 8,100,000 INGOT TONS PER MONTH ISHED STEEL PRODUCTS 1942 ning Post, Time, etc., came the conclusion that the would jeopardized for lack ore, and some papers freely proph- esied the end steel su- premacy. some the shock was somewhat akin seeing Santa Claus zoot suit. However, all the worry seems the author like borrowing trouble, worst there years’ supply, and since most reserves are set extremely conservative basis, there every likelihood 20- year supply. Lower grade reserves are unlimited, and what with im- provements beneficiation inevi- Product Semi-Finished (for shipment) Structural Shapes ails Bars AND Pipe and Rod and Wire Tin and Terne Plate Sheet and Strip Miscellaneous Total table that period, the swing over the poorer ores when the time comes will likely gradual and cause hardly ripple, either technically cost-wise. Recently, also, Canada’s Steep Rock ore body has again hit the limelight the salvation supposedly ore hungry mills. Julian Cross’ Steep Rock property well known de- posit which sucked considerable money the 20’s. The geology and metallurgy the lode was for the first time described detail THE IRON AGE (July 20, 1939). The ore excellent metallurgically, but un- fortunately lies the bottom Per Month 700,000 375,000 1,300,000 185,000 430,000 370,000 250,000 5,780,000 (69,000,000 Net Tons Annually) PLATE ROU BLOOMS NDS PLATE TERNE PLATE PLATES SKELP TERNE HOT ROLLED COLD FINISHED BARS HOT ROLLED STRIP COLD ROLLED STRIP COLD ROLLED STRIP oF RILLETS ALLOY BARS WIRE TOOL STEEL BARS SPLICE BARS TIE PLATES RAILS STRUCTURAL- PILING WHEELS FORGINGS THE IRON AGE, January 1943—53 4 q 4 | 4 7 t . | t | the lake, the draining which and opening pit would involve con- siderable money. said that the Canadian government run- ning power into Steep Rock and intends put rail line into and build port facilities Port Arthur. while the United States will finance opening the ore body. Right now, however, the proposition seems little confused, and there little expectation that Steep Rock will have much participation the var effort. Serap, 1943, will require most its full share the steel load. While Mr. Batt has stated that the scrap section WPB one the most efficient divisions, some ob- servers Rosenwald’s conserva- tion division find difficulty de- tecting very much realities inspiration from that direction. The headaches 1943 are going migraine char- acter unless little more realistic price schedule established and successive civilian drives are more 54—THE IRON AGE, January 1943 1942 closely integrated with fessionals that the junk can pass ing order- stream. Still relatively fairly good scrap the many slag dumps around the country. 1942 tons this mate- rial was salvaged, with Republic the biggestsingle participant. and certainly 2,- 000,000 tons easily realized 1943 operators can some way pulleys andhandling equipment. One discourag- ing permanent loss excellent scrap and even more strategic tin the wretched muddling tin can salvage. 1942 less than per cent the tin cans used went through the hands detinners. Estimates are that during 1942 there was detinning for processing cans nearing 500,000 tons per year. Shipments “pre- pared” cans were probably never the rate greater than 60,000 tons per year. Therefore, evi- dent that very considerably over 1000 tons recoverable scrap and tons tin were irre- vocably and needlessly lost each day. The fact that there were nearby detinning plants certain areas was far from insuperable difficulty. for instance, was receiving Neville Island, Pa., shipments “prepared” cans from such distant points Texas and Florida. the New York area people still are not being asked clean flatten cans, the recovery therefore being only fraction the potential. most other sec- tions the country, civilians were told not save their cans, whereas many these flattened shredded cans could have been shipped detinners who still had unused pacity. And while shredders and detinners are being built over the country, even pub- licity campaign could have urged civilians save and accumulate their cans create backlog material for the plants when they went into operation. None this was done and surprisingly small percentage cans being inter- cepted before reaches cinerator dump, the consequence being the loss million tons steel scrap and many thousands tons tin. for the future, much the heavily tinned cans will the military and will not recoverable, and all the new de- tinning plants will finished about time receive the increasing stream lightly tinned lac- quered cans now going into civilian consumption. the proper segregation dling alloy scrap the country’s industrial plants, and fact the entire alloy steel position de- pendent far more care and forcefulness this practice. With proper segregation the ferroalloy requirements for steels can dropped almost negligible point. For munitions, probably less than per cent the steel gets the battle fields, while the remainder now flowing back flood alloy borings and turnings which becoming quite serious problem. Unless greatly in- creased briquetting facilities are installed there will not full utili- zation made this valuable ma- terial. Since the electric primarily melter selected scrap (being relatively inefficient re- finer for removing carbon, phos- phorus and silicon), the necessary millions tons plate clippings and phosphorus structural scrap just not exist. Even now sometimes necessary ship crop ends long distances from roll- ing mills serving open hearths hungry electric steel plants. There will completely inadequate sup- ply high-grade, low-phos scrap electric furnace output 1943 despite such expedients the use numerous open hearths melt down unselected scrap poured into ingots and analyzed for use | q q | aaa electric furnaces. For instance, the entire output Mansfield Sheet Tinplate Co., company currently remelting scrap and pouring into ingots, goes Republic and Timken price with OPA per- mission, above the market. Over million tons aircraft quality alloy steel ingots alone are expected 1943, and several com- panies are taking unprecedented steps ease their scrap problem. Copperweld Steel Co., for instance, one several companies setting triplexing scheme, whereby alley scrap may melted cu- ladle with caustic soda, blown bessemer remove carbon and silicon, and subsequent chemical dephosphorization mixer, then charging hot (or cold) into electric furnaces. Republic, the other hand, banking direct re- duction, so-called sponge iron, unit Warren, Ohio, turn out small volume high grade melting stock, hydrogen tion magnetite concentrates. Planned output 100 tons day, the plant cost about $450,000. successful, the 100 tons would take care about Re- publie’s scrap requirements. This venture came the climax al- most year political, technical and emotional wrangling about the practicability widespread con- throughout the country. The spokesman for sponge iron enthu- siasts was Senator Joseph O’Mahoney Wyoming, who was vocally suspicious the technical vision established steel makers and inclined read fear ruin- ous competition the motive un- program. Steel makers, other hand, were very conscious the miasma technical and economic uncertainty ever blanket- ing all direct-reduction schemes, and were particularly fearful sponge iron construction draining off equipment badly needed tions already far behind schedule. The compromise $600,000 ap- propriation for Bureau Mines experimentation with its own pet rotary kiln direct reduction scheme Laramie, Wyo., and Boulder City apparently satisfies Senator and matter mostly academic interest the steel producers. has been said that the 1942 Krupp-Renn pro- cess, originally the autarchy movement under Hitler exploit German siliceous low grade ores, being used the new Hermann Goering Works, and also the Japanese. How- ever, the most re- cent advices are that neither coun- try using di- reduction process. numerable schemes for di- which tured industry and like May flies have had only brief afternoon ex- istence, the Bras- sert-Cape process employed far the most promising, and was scheduled for approval Hauck WPB long before the started flailing the industry. Technically pretty sound, but even more im- portant being designed experienced and highly skilled en- gineers, and will operated smart steel personnel. Herman Brassert engi- neer considerable renown, and his company has designed numer- ous blast furnace units here and abroad. Cape has worked for both the Steel Corp. Duquesne and for Republic, later forming the Coast Metals Co. experiment with metallic sands the Pacific Coast using the Herre- shoff furnace. Apparently Mr. Cape will associated with Brassert only the Republic unit. The process itself consists essen- tially two steps: (1) Ore treat- ment and purification, (2) reduc- tion and compacting the reduced material the softening point. The iron ore crushed until very fine (less than mesh) and then subjected the most suitable con- centrating methods, such grav- flotation, magnetic elec- Henry John Kaiser (Barnum trostatic separation, followed gravity air tabling. The result quite pure mineral may contain only small percentage gangue, which then may fed the reduction unit. The reduction takes place under- neath Herreshoff furnace which serves prepare the ore for the final reduction. The furnace used industry for variety purposes, for instance for roasting copper and other non- ferrous ores. (It vertical cylindrical unit with number superimposed hearths which are provided with rotating rabbles rakes. can heated num- ber means. The ore charged the uppermost 20-ft. diameter hearth (see drawing page 63) where mainly dried and then, entering the furnace body, begins heated, roasted, calcined, prelim- inarily reduced, finally enters the reducing hearth. The rabbles have propelled the ore through the upper floors where heat- either the hot spent reducing gases alone, also conditions the burning part THE IRON AGE, January 1943—55 > : i | | | ) | y | O )- e | 7 1942 counter current principle, i.e., the dropping ore into rising cur- rent gas, but then, the heaviest els fastest and ar- rives incompletely reduced the bottom the fur- nace. the Cape process, the charge con- stantly agitated hot reducing gases keeping fluidity and blow- ing slowly toward the dis- Gas locks are con- turned over and over, always sus- 1943's promise that CMP will phere. Finally the comfortable fitting suit, not reduced material, iron grains reach these gases (which still contain chute which feeds combustible constituents) one briquetting rolls compressed the upper floors the Herres- under reducing atmosphere hoff furnace. 500 per. sq. in. more The reducing hearth rather higher specific gravity desired, ingenious design.. Here the eral fed into V-shaped troughs across the bottom which are nar- row slots and reducing gas blown through them against the light, powdered ore particles which are made bubble the impact the gas. fact the ore bed has as- sumed state equivalent fluidity its own accord along the slotted hearth. This method propelling the charge assures the slow advance the heavier and faster advance the lighter par- ticles and nearly proportional the degree progressive reduction. The depth the bed ore upon the final reduction hearth can kept between and in. depth. Many inventors have tried work their reduction process 56—THE IRON AGE, January 1943 § into briquette. The finished material may run per cent Fe, per cent gangue, the remainder being oxides. expected that the tempera- permit optimum reduction rate while keeping the temperature low enough prevent fritting and sticking the individual particles. The oxygen content may possibly removed per cent with- comparatively short time (20 min.) with gases high hy- drogen the operating tempera- ture 1100 deg. using Eastern magnetic ores. The reducing gas should there- fore preferably mainly hydrogen, and coke oven gas, reformed nat- ural, water gas can used ad- vantageously. must gas with maximum H./CO ratio and minimum content hydro-car- bons, carbon dioxide and nitrogen. sulphur, and the gas must ade- quately purified and conditioned. must pass through the burden temperature 1100 deg. and ture slightly above that. large part the product most proces- ses “sponge”, porous honey- combed product with incompletely reduced iron surrounding and cov- ering the The sponge oxidizes rapidly air and has subjected mechanieal work moderately suited for technical purposes. Thus, “sponge iron” not comparable with the ly” produced iron and steel, either quantitatively qualitatively. The melting stock uniquely ob- tained compression “nascent iron” into briquettes reducing atmosphere. Pressure the briquetting machine can adjust- produce iron most any density and shape, since the face the nascent iron particle, i.e., the iron granule which has just been reduced from its ore, has consider- able chemical and physical surface reactivity. The facility with which the melt- ing stock can made any shape and density (below specific gravity about 8), preliminary small- scale experimentation, has natur- ally given rise the idea that per- haps sheets shapes may eventu- ally turned out directly from the unit. This idea seems like powder metallurgy gone “Kaiser,” and not much attention being given the moment. The Brassert-Cape undoubtedly run into considerable operational difficulties first, for such seems the fate all commercial plants. Undoubtedly, the hydrogen reduction far more promising than carbon reduction used most other schemes. Only actual opera- tion the plant will prove its via- bility, and quality and cost will de- termine its adoption elsewhere. Having excellent Port Henry and Chateaugay concentrates, and avail- able desulphurized coke oven gas Warren, Republic ideally fixed give this scheme limited whirl. General opinion that the man- hours involved the direct reduc- tion will more than offset the fuel saving, and over-all cost may several dollars ton more than for pig iron. | q Publicist Nitens Excelsos Whether the problem was steel, non-ferrous metals, aircraft, ship- building, medicine, ning the love cycle barnacles, the one individual who 1942 knew all and told all was Henry John Kaiser. While the impact Kaiser industrially was negli- gible proportions, his deification the man the street was one the seminal developments 1942. Mr. Kaiser, the man, most likeable individual, who has mellowed considerably the rough and tumble days contract- ing, and even within the past year has shifted from brash desk thump- ing and bellowing speaking softly (and often) and carrying the big stick implied support from the Boss Man himself. While less than two years ago bug-eyed interviewer for the San Francisco News described Kaiser the publicity-shy Oaklander, the intervening years have seen his curious development into admin- istration foil for big business, and fervent adoption politicians, many newspapers, Time and Life magazines, well-known columnists and other assorted practical visionary dragging along great mass hopelessly moribund, reactionary and selfish ‘industrialists involved the war effort. Mr. Kaiser has become something fetish and seeming- one dares question even those statements that reach the zenith illusion without risking being howled down reaction- ary with questionable motives subversive nincompoop. Certain Kaiser’s subordinates, conscious his careless weaving apologs, describe his talking process thinking out loud the buckshot manner, spur every- one heights effort. That, itself might well commendable such thinking didn’t always car- the implication that practically all other industrialists were ignor- disinclined give all support the war effort. And, this writer finds hard understand how all- out war production furthered constantly lambasting the automo- bile industry for its past interest business usual, and then ad- miring Kaiser’s lofty advice them immediately design, plan production and ments for automobiles deliverable @and then have 1942 in, say, 1945; or, succession timed publicity gags that are en- tertaining but none the less enervating all sucked in; or, for all companies sweat through priorities their building plans into the common effort, even such straight thinkers Raymond Clap- per admire Kais- er’s steel from warehouse tion initiative sadly lacking others. That was jolt some producers who had made the steel and were that same time unable certain their own badly-needed lack steel pri- orities. While the writ- certainly has desire dwell pediculous minutiae, might some interest see how Kaiser’s statements jibe with the facts. Oddly enough Mr. quently states that was the first put pneumatic tires wheelbarrows. The rubber companies fail verify that. And, frequently, Mr. Kaiser states that does the impos- sible, and that everyone said that couldn’t build Boulder Dam. That must come surprise the Army, which surveyed the site, and let the contracts, which Mr. Kai- ser participated the extent perhaps one-fifteenth.* The other fourteen-fifteenths never heard from. (See footnote page 58). One the next big Kaiser splurges was Hansgirg’s process had had indif- ferent success several foreign countries accompanied fatal ex- plosions, but any advice against Tactically more money and secur- ity, strategically prominent place management's table. Kaiser’s adoption the process was construed either ignorance the frenetic monopolists protect their posi- Kaiser purchased Hansgirg’s patents for $750,000 and built Permanente, Cal., enormously costly and complex installation, which due course had its several fatal explosions. And various was startling hear Kaiser state that was usual far ahead schedule and had lutionized the magnesium business when, the same time Permanente wasn’t even remotely meeting pro- duction promises, which turn was having considerable delaying effect the 1942 war Through exercising great care, the danger explosions Permanente has been more recently minimized, and the magnesium dust from the reduction furnaces now quenched with natura! gas rather than hydrogen. Permanente’s raw THE IRON AGE, January 1943—57 a- a- le- il- ‘as uc- uel for material longer comes from the “unlimited” reserves Nev., but now Salinus, Cal., which mixed with sea water Moss Landing. Since there every indication that the large electric reduction furnaces will never approach pro- duction expectations, small sin- gle-phase furnace currently being experimented with determine its suitability. Kaiser also using the Salinus dolomite newer Pidg- eon-process plant Monteca, Cal., which already partly produc- tion, are number other sim- ilar plants elsewhere the coun- try, which were built and are oper- ated companies never before the magnesium business and appar- ently not publicity conscious. regards Kaiser’s steel effort Fontana, Cal., the overtones and ramifications are rather interesting. There seems carefully nur- tured popular illusion that the mak- ing steel the Pacific Coast another demonstration the Kai- ser magic touch, whereas conven- tional steel makers such operation impossible. But that was never the real difference opinion. *The financial relationships among various so-called “Six Companies” «on tractors are complex and varied that the finger put any fixed per- centage. In February, 1931, the follow- ing six contractors formed corporation for the construction Boulder Dam with subscribed and paid for $100 share or a total of $8,000,000. Of this amount was paid cash and subscribed follows: Macdonald and Kahn, $1,000,000; $1,000,000; Bechtel-Kaiser-Warren (com- bination), Morrison-Knudsen Co., $500,000; Shea Co., $500,000; Pacific Bridge $500,000. much the one and half million Kaiser had minor part originally. Later Bechtel sold part his share Kaiser the origina! deal. Since Boulder Dam, the following additional contractors are garded among the “Six Companies” group: Bechtel Co., Bechtel-Mc- Cone-Parsons Corp., General Construc- tion Co., Henry Kaiser Co. subsequent projects, such the San Francisco Bay bridge, the Bonne- ville Dam, the Oakland Broadway tunnel (which was failure and which quit without completing), Parker Pacific Naval Air Bases and cently Permanente Cement plant, Perma- nente magnesium plant and the various different combinations the group have been represented various shares. seems generally assumed Macdonald Kahn and probably the Utah Construction Co. are the and therefore have larger share most the projects, financially. One the group is manager and responsible opera- tor each project. shipbuilding the Pacific Coast at the present time, Bechtel-McCone-Parsons operate Cal-Ship at Los Angeles, W. A. Bechtel Co. oper- ates Marinship Henry Kaiser Co, operates four Rich- mond and three yards Portland. Two Permanente Metals Corp. and one Portland operated the Oregon Shipbuilding Co. Kaiser supposed have eight nine per cent Cal-Ship and in Marinship and conversely Bech‘el and probably others the original group have shares the Kaiser operations 58—THE IRON AGE, January 1943 Steel has long been made the Pacific Coast, based limited supply local scrap and pig iron from Utah from Sparrows Point, Md. The difference opinion dealt with the feasibility Cali- fornia blast furnace make pig iron there. And, while may ease the gnawing inferiority complex the California Chamber Com- merce, this writer certainly still the opinion that increasing the less photogenic Utah pig iron pacity (which being done Steel) far more sensible, tech- nically and economically measure, than building blast fur- nace California. Kaiser’s Fontana mill will cost least $55 million, which $48 million RFC loan, and will consist blast furnace, by-prod- uct coke ovens, open hearths and plate mill. Almost before the plant was above ground level, request for additional $75 million was made for soaking pits, blooming structural mill, merchant mill, and several electric furnaces. Cost engineering was probably the neighborhood million and currently practically completed. Some 4000 5000 people worked the construction job and there apparently adequate pool both skilled and unskilled labor. The entire plant couldn’t possibly more conventional design, the one unique feature being that con- struction makes provision for earth- quakes. Some Los Angeles experts are charge design and have insisted many features not gen- erally agreed other engineers. The blast furnace will have spe- cial structure supporting it, tied the mantle. Stoves are bolted down for this reason. The dust catcher has columns large have been used for smaller blast furnaces, with 12-in. beams for diagonal bracing, and about diameter bolts per column. The open hearth building will have bays back the charging bay and there will one along the pit side, both throughout the entire length, for earthquake bracing the main structures. The cost the earthquake protective installa- tions estimated million. Kaiser keeps insisting that his schedules will usual met bettered, i.e., pig iron Decem- ber, 1942, ingot February, 1943, and plates June, But noth- ing short miraculous completion many items will permit rated pig iron February, ingots August, and plates the end 1943. None the less, even though many other blast furnaces elsewhere the country have will into blast with hardly stick pub- licity, Mr. Kaiser apparently had big show all scheduled for the Fontana furnace Dec. 22, with Nelson, considerable military gold braid, bands, bunting, infinitum. The plans apparently have quietly expired have been delayed, either because Mr. Weiss WPB has been unable lift eno