The Iron Age 1943-02-11: Vol 151 Iss 6

1943 ngth and price ware- ints; base. area Co. 2 0c. . and t an Co. stern base Jap Cruiser Mysteriously Disappears serve the silent service. First strike the enemy his home waters, the officers and men our submarine force are still taking daily toll enemy ships. These men our submarine forces know engines. For they literally live with and the Diesels which carry them their enemies bring them back. Many those engines are Fair- banks-Morse Diesels. are proud their performance record. are glad that can thus serve the officers and men who man the sub- marines the United States Navy. ic- — 4 “Ours operation but carry spare “This day-and-night process and our equipment run continuously. But don’t even bother carry spare parts for our writes the Plant Engineer Eastern corporation. “Years ago, began discarding other types drives favor worm gearing. first began installing Clevelands 1923 and have bought more than them far.” Continuous operation your plant these times even single break-down can disastrous. Cleveland Worm Gear Speed Reducers can help you secure the same trouble-free machine operation. For over years, Cleveland has built Worm Gearing exclusively—has grown the largest manufacturer the industry. will glad have Representative call. The Cleveland Worm Gear Company, 3252 East 80th Street, Cleveland, Ohio. Affiliate: The Farval Corporation, Centralized Systems Lubrication Canada: PEACOCK BROTHERS LIMITED WORM GEA THE IRON AGE, published every Thursday the CHILTON CO. (INC.). Philadelphia under act March 1879. vearly North America and South America, Foreign $15. Vol. 151, No. > ; a Entered second class matter November 1932. the Post Office A 4 / Me Dog é | ot 4 q ‘ FEBRUARY 11, 1943 VOL. 151, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° ° ° Managing Editor, LIPPERT Technica! Editor, OLIVER News Editor, JAMES Associate Editors Editorial Assistants Resident District Editors Washington Pittsburgh Washington Chicago Cleveland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis BACON Seattle ° ° DIX, Manager, Reader Service ° ° Advertising Staff bert 621 Union Bldg., Cleveland Hern Chilton Bldg., Philadelphia Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, 100 East 42nd New York Lewis, 7310 Woodward Ave., Detroit 100 East 42nd New York arren, Box 81, Hartford, Conn. on, Market Research Mgr. s, Production Manager. ur, Typography and Layout. ° ° ° ember, Audit reau Circulations Associated Business Papers the Industrial Arts Index. Pub- Thursday. Subscription Price America, South America and ‘U. Foreign, $15 year. Copy, cents, Annual Number, Cable Address Y." Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Sts. 100 East 42nd St. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, DUFFY CHARLES HEALE This Week in... THE Will Everybody Lose the War? Technical Articles Forging and Welding 1000-Lb. Aerial Bombs Welding Gas and Aircraft Steel Cracks Are Sharp Cutting Edges Necessary Rough Cuts? Electric Arc Hot Topping Molding Machine for Women Extruding Coatings Welding Electrodes Quick Healing Burn Characteristics Non-Ferrous Casting Technique Correct Clip Fastening Procedures New Equipment: Machine Tools 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 Comparison Prices Finished Steel Prices Index Advertisers. Copyright, 1943, Chilton Company | | } 146 154 155 ° ° ° | 7 Reporting Current Steel Stocks you may know, the steel warehouse industry entered the war period with large and complete stocks. These reserve stocks steel enabled industry switch over quickly from peace war production. However, the process, stocks steel the warehouses the country became seriously depleted. fact, these great sources emergency steel became almost non-existent. matter how carefully plants are maintained and production pro- grams scheduled, there are always times, particularly heavy war load, that certain lots steel must secured immediately production imperiled. companies working top speed and embarrassed their inability secure steel quickly from warehouses, began reporting their problems. The War Production Board was quick grasp the situation and assign special allotments the warehouses. bad situation now gradually being improved and are glad report that our stocks are somewhat better assorted. order eliminate the time required for many roll changes and permit increased overall production steel, are concentrating the most generally used sizes. spite this curtailment our usually very broad range sizes are now better able serve than any time recent months. When you need steel have problem selection fabrication, get touch with your nearest Ryerson Steel-Service Plant. Our engineers and metallurgists will glad work with you. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. RYERSON 46—THE IRON AGE, February 1943 Will Everybody Lose the War? AST week, wrote about the common denominator that must found between capital and labor this country not only win the war but win the peace. The peace will won—and the war too, not only succeed making this better country which live than any other country the world—it has always been that—but making America even bet- ter industrially, than has been before. Better for everybody. This year, for example, will pile the world bonfire and burn the equivalent whole year’s work every wage earner, every salaried person, every professional worker, every domestic and public servant. And addition, shall pile and burn war the equivalent every dollar profit earned every stockholder employer and every dollar income received every recipient insurance, annuity pension. That what will mean spend $100 billions for war 1943. man, and nation, can burn year’s income and expect not feel it, especially when already had gone into debt previously almost equal amount. And that exactly our status. Any man that situation would know that would have work harder than ever and produce more than ever just get back where started from. And exactly what America will have do. expect better our situation the future, let alone getting back where started from and let alone feeding, financing and FEBRUARY 11, 1943 rebuilding the rest the world, shall have keep every factory this country, every mill, every mine turning out useful and needed prod- ucts for peace, just are now turning out needed products for war. ESTABLISHED Because products, not dollars, are wealth. this were not true, all would have would start the printing presses rolling and turn out enough $10,000 bills make every- body happy. But there were not things enough buy, the money would not much good. ° ° ° ° Capital, management, and labor have declared truce for the duration the war, which with some exceptions pretty well observed. But this not enough. What needed not truce, which means temporary cessation hostilities, but declaration peace and firm resolve work together. know now, from our experience the past year, that American management and labor can perform miracles production when they make their minds and forget their differences. And those differ- ences, the past, have largely concerned the question the division total that apparently was not enough around. The great common ground for everybody produce much that will enough around. Enough not merely around, but pay something off each year the staggering debt that will confront when the war ends. just stop fighting the Japs and the Germans afterwards and resume fighting each other for share that which everybody will have lost the war matter who wins it. | | AG F q But, Home Front Accidents Exceed War over 150 Home front accidents are occuring the yearly rate about 100,000 killed and 9,000,000 injured. Compared with America’s Army and Navy war cas- ualties 58,000 during the first year war, the ratio one fighter lost more than 150 Ameri- cans killed, permanently disabled, injured. This ratio tragic. tells the grim story lost war production—of thousands planes, tanks guns, shell, that never will reach our fighting men. Where most home front accidents Traffic and public accidents accounted for 53% the total killed and 34% the injured. Home acci- dents resulted 30% the deaths and 49% the injured. On-the-job accidents accounted for 17% the killed and 17% those injured. Inci- dentally, these figures prove that workers are safer the job than they are anywhere else. Conservation manpower tremendously im- portant, not only when men are the job, but Wy YY N Wy Wy Yy, throughout all their active day—on the street, recreation, and home. Inland, with one the best safety records the steel industry, taking every possible step conserve manpower—by maintaining large and efficient safety department, and thoroughly equipped clinic—by constantly coaching men safety inside well outside the plant—by cooperating with local agencies, and subscrib- ing the War Production Fund Preserve Manpower. Act now conserve manpower and increase war production! You can help making sure that your Safety Program does not lag. Enlist today the national crusade against accidents. Write for full informa- tion the National Safety Council’s War Pro- duction Fund Conserve Manpower, Chrysler Building, New York, WY MQ Yh, yy U yy yyy missing and the Office War Information reported were aerial bomb. Forging and Welding 1000-Lb. Aerial Bombs Seamless tubing nosed down hot form the main body and tailpieces which are then arc welded after being machined individually. Several contractors parts this job and all them improvised existing equipment get under way fast. NEALEY Ordnance Department, Army present war the first one which bombs dropped from airplanes have become major factor. The tonnage bombs used colossal strain the avail- able facilities for making them, great these facilities are. meet the demand, bombs are being every way possible, long they meet the rigid requirements the Ordnance Department the Army which responsible for their design, manufacture, procurement and maintenance. High explosive bombs are divided generally into two classifi- cations, demolition (or general pur- pose) and fragmentation. Both con- tain high explosive filler, either TNT amatol. Fragmentation bombs, gen- eraily speaking, are relatively small, with the wall sections specially de- signed for effective fragmentation. Information the sizes this type against personnel, restricted. Demolition bombs range size from 100 4000 lb. maximum charge explosive desired, the steel body made light con- sistent with the strength necessary withstand impact stresses. Usually the explosive charge about half the total weight the bomb. The explosives used are insensitive that they will not detonate upon striking during penetration, therefore more sensitive detonators and boosters are added make them explode. are put the nose and tail con- trol the time detonation and fins are added the tail insure their dropping nose down. Equipment Rebuilt One method bomb production, for the 1000 Ib. size, Fig starts with seamless tubing pipe low alloy steel the raw material. From this the nose and tail ends are hot formed, machined and then welded together. one plant (which formerly built freight cars day), portion its space has been tooled for bomb manufacture the manner described above. The building used some 1500 ft. long and the bays are served with and 10-ton overhead cranes. Starting late the war program, this company found practically impos- sible obtain when needed the neces- sary machinery, furnaces, conveyors, and 40-year-old presses dozers had hand, purchased even older ones, and extended their life expectancy also. Redesign was neces- sary because they were originally built for entirely different work. They were the hydraulic type and was necessary, among other things, lengthen the columns. The bomb metal THE IRON AGE, February 1943—49 x | 2a j — — ls ° ° ° ‘ ° ° ° 4 ib- | var ety | nal | : gir 2—Type gas cutting fixture originally used. Later these were replaced ma- 4—Partially form chines similar the one shown Fig. bomb bodies being handled and out the aid tip-up rigs and roller conveyors. 50—THE IRON AGE, February 1943 the furnaces with was hard that soon chewed holes the bolster plates and was neces- sary obtain scrap armor plate and make filler blocks for the bombs dropped on. The amount work required was prodigious. Hydraulic pumps were rebored and redesigned for increased capacity and working pressure which turn made necessary the addition modern, high pressure lubricating forcement, ete. tors were rebuilt step pressures from 600 1000 per sq. in. This was accomplished reboring larger dimensions and increasing the weight and size the ram. This latter was done casting tons special pie- shaped weights, fitting them around the ram and bolting them it. Regu- lar press makers needed months this, along with their previous commitments. This company, work- ing its engineering staff hours day, seven days week, did three months. Furthermore, design- ed, redesigned, experimented with and built its own furnaces, hundreds them. constructed its own roller conveyors. And then, when everything was ready and production started, the company ran slam-bang into metal- lurgical difficulties that took guts and sweat lick. single production line here con- sists the furnaces and presses the nose and furnaces and presses for the the start the line the cutting department. Random lengths pipe ft. long, and approximately in. dia. enter the plant flat cars and these are trans- ferred cranes series cutting tables. These tables were made bending and shaping car plate form angles, and welding them side rails, legs and cross bars and fitting rollers between. Cutting done with torches using cheap city gas in- stead expensive acetylene. The cost gas insignificant and its use re- quires only per cent more addition, city gas leaves much softer surface, resulting tion subsequent machining time. first, cutting fixtures were used track which clamped around the The torch, fixed pinion gear mesh- ing with ring gear was moved around the pipe while cutting ing small handwheel, Fig. Grief was immediate and persistent. Tube rolling mill tolerances were naturally beyond the tolerances permitted bomb design. Unevenness the tubes caused uneven cutting for was nec essary that both ends tube length absolutely square and each other this determined whether FIG. 3—Circular furnaces especially built for heating the bomb noses. and vork and and nade high rein- This eight was netal- con- es for ine dom and the trans- utting form side fitting done in- cost xygen. much reduc- used pipe. mesh- moved Grief Tube turally ted tubes length allel they set squarely the platen the press angle. Any such defec- tion, together with uneven cuts, caused buckling and folding when drawn hot the dies. Gas Cutter Built This requirement made necessary design and build cutting machine that would cut evenly, squarely and parallel. This unit comprises long horizontal table fixture holding series rollers that the pipe can pushed along its length. one end motor driven chuck turn the pipe and intervals along its length are offset pairs small wheels mounted air lifts. When the pipe has been pushed into position, these wheels are elevated and the work given complete turn. The torch stationary. This assures square and parallel cuts. make the cut even, small wheel attached the tip end the torch and this wheel rides the pipe while the flame cuts. Re- gardless unevenness the pipe it- self, the tip always held the same distance from the pipe which prevents any variation width cut. Hot pressing these lengths pipe shape ticklish proposition and the heats, shape dies, time and length strokes, amount draw each die, and the rest the program developed here were the outcome considerable research, and trial and error. The problems were solved and without resort male dies. The first difficulty was the unevenness the pipe itself, which led distor- tion the press unless considerable care was exercised. Then again, the temperature had right, for the material was too hot, would buckle fold, both. first was thought necessary obtain sharp division between hot and cold metal, the furnaces were constructed with the circular openings just large enough allow the pipe enter and cooling Water rings surrounded the pipe the outside. This proved satisfactory the first operations, but later definite ridge appeared the contour the ogive (nose cure this, the noses were pulled out the furnaces slightly just enough let the flames lick along the sides the metal and thus pro- duce gradual heat. Temperatures used range from 1700 2200 deg. Special Furnaces Designed There are from furnaces press depending upon the type operation and the heat required. These furnaces are circular shape, about ft. diameter and in. 5—The final forming operation the nose performed pneumatic drop hammer, using male punch. this point, only female dies are used for nose forming. 6—Scarfing the tailpiece the bomb prior welding the body. The work rotated trunnions under the fixed torch. similar set-up now used for gas cutting the seamless tubing. RIGHT 8—Boring the nose the tailpiece vertical turret lathe. 7—Hollow milling operation nose bomb. THE IRON AGE, February roller thing the q S 9—Threading operation the tail, using collapsing die head. deep, Fig. Constructed fire brick laid circular steel shell, each fired four gas burners and has vertical vent built onto the back for the escape the products combus- tion. Air supplied oz. pres- sure and the gas pressure cut regulator. Roller conveyors are laid the floor front the furnaces and the pipe lengths are pushed along these. front each furnace tip-up rig which the pipe tip- ped horizontally that the end can pushed into the furnace, Fig. The outer end the pipe covered with plate prevent the escape heat through the center. The first operation 1000-ton vertical, hydraulic press with three hydraulic cylinders and three lifting jacks pull backs. The female die attached the upper platen and there nothing the lower platen except gage which locate the work. This press forms the end the pipe into truncated cone, bring- ing the approximately in. diameter pipe down 14% in. nose opening this first operation. this time, much heat has run into the unworked portion the pipe that immediate reheat would soften the body cause buckle fold the next operation. Therefore, allowed cool and cooling floor parallel roller conveyors provided for the ebb and flow material this point. The next operation upset 700-ton press the same type al- ready described. After reheating the small end the pipe, the metal here thickened this point from in. (according the variation the wall thickness the pipe) pushing down the hot rim about in. The second, third, fourth and fifth draws are formed quick suc- cession, all with reheat but without cooling between. The same type presses and furnaces are employed and the nose opening brought down 52—THE IRON AGE, February 1943 3%, and in. respectively. The nose contour next formed reheat and the same type press. The last forming operation, re- quired, accomplished with 2500- lb. drop hammer, Fig. the last reheat. This the only forming operation where resort had mandrel male die. means hydraulic ram, the bottom female die pushed clear the hammer for J « 5 10—Fixture used tack weld the two parts the bomb together. loading and the bomb dropped into nose first, after which pulled into position under the hammer. The ram then forces the male die down into it. Operations Tailpiece The first operation the tail piece hot forge one end truncated cone shape, with diameter opening 13% in., 300-ton bulldozer. second operation, another bulldozer, brings the end down in. diameter and final forming ac- complished third bulldozer for sizing. The work heated re- heated for each these operations tween. The female die used the first two operations, but both male and female dies are employed the third. Both halves this bomb are checked with ring gage allowing 1/16 in. tolerance. The two ends matched for welding are then be- This done with the same type gas torches, Fig. were employed cutting. Trucked another plant with avail- able machining capacity, the nose half supported steadyrest and ro- tated means special faceplate which attached. Tools mount- turret then drill the lead hole; first and second bore the fuze hole; face end; face; contour tip nose, Fig. and finally thread the fuze hole with collapsible tap. The tail end put vertical turret lathe and the end faced length, Fig. The hole threaded with collapsible tap, Fig. while the nose held pneumatic chuck. The halves are then shipped third plant with large furnace pacity that could used for anneal- ing. happens sanitary ware manufacturing plant with large number vitreous enameling fur- naces for products large bath tubs. immense welding shop has been set and also welding school. Here the halves are welded together into complete bombs. Electric welding employed. Due the non-uniform- ity the wall thickness resulting from the tolerances seamless tub- ing, the two sections the bomb are matched for thickness before welding. Arc Welding Operations Next, the tail portion put into upright fixture, Fig. 10, the nose section set top and the two halves are tack welded together. The metal this joint then preheated some- thing like 600 deg. This complished rotating the tacked bomb fixture equipped with motor and pushing twin gas and air torches through the open (rear) end that their flames will play the metal. Welding performed similar fixtures with four rollers turn- formed this rotating fixture. Three beads are laid down. a per- motors, Fig. 11. The bombs are rotated slowly—at welding speed —one revolution every min. Three beads are laid and the flux chipped off each pass with pneumatic chisels. Grinders and chisels are smooth the completed weld, which allowed protrude more than 1/16 in. above the surface the out- side and in. the inside. Lugs are also welded for handling the bombs the field and the planes. Welds must uniform size, width, smeothness and reinforcement. Cracks any nature extent weld metal plate cause for rejec- tion. Surface defects such marks, gas pipes, slag pockets other surface irregularities are not accept- able Ordnance inspectors. Also welded surfaces should merge smooth- into the plate and and rolled lapped edges welds are not permitted. further specified that offsets the welded joint shall not exceed 0.06 in. Rigid radiographic examination made the welded seam one out every ten bombs made further check the quality the welds. The bombs are then normalized 1600 deg. for hour muffle, gas fired furnaces. These fur- naces are about ft. wide and ft. deep. Heat supplied three natu- ral gas burners each side firing the space below the hearth with the hot products combustion pass- ing around the muffle. The bombs are lifted and out the furnace longhandled fork suspended from chain, Fig. 12. The furnace doors are opened and closed electrically push buttons located the handle the fork. The bombs, heated, rest bucks which turn rest the hearth. During heating, the threads the bombs are protect- protecting plug screwed into the nose and protecting rig screw- into the tail. Each bomb tested hydrostatically for min. and the welds observed for porosity and strength. The lugs are tested 8000 with hydraulic jack. Shot blasting inside and out now resorted and the setup for the first includes roller tables and series booths. The bombs are rolled front apertures the booths, tail first, and shot blast nozzle track inside the booth, moves slowly forward into the bomb, blasting progresses. The bombs are then load- into fixtures suspended from overhead chain conveyer, Fig. 13, and are moved through one large booth some ft. long and ft. high. Here 12—Handling bombs and out the annealing furnace. Push button control for the furnace door the handle the long fork. Fig. bombs the sand blasting conveyor. THE IRON AGE, February as : in ‘ed er IS A ng > ire ng. ABOVE inspection follows the plac- ing the protecting rings. RIGHT 14—Spray painting the interior the bombs done automatically with this equipment. The spray gun lance traversed into and out the work power. Spray painting next order and booth with water curtain back employed. The bomb rotated motor driven fixture and operator with hand spray covers the inside weld give extra coat. Then long spray nozzle short, motor driven closed loop chain moved slow- forward, spraying the entire in- side surface, Fig. 14. The threads are still protected. overhead closed Pure Gases makes absolutely difference the fissure-formation tendency either unalloyed alloyed aircraft steels whether the acetylene used for welding drawn from cylinders direct from generators, according investigations the effects impuri- ties welding gases the tendency crack formation welded chro- mium-molybdenum aircraft steels, re- 54—THE IRON AGE, February 1943 loop chain conveyer now carries the bombs through another booth where operator sprays the outside. This conveyer some ft. long pro- vide drying period. hasten the drying the interior coat, blasts air are forced into the open ends the bombs they pass along. The shipping bands, protect the lugs, are put after drying, Fig. 15. transferring the bombs from one Metallbearbeitung. Other conclusions arrived these studies were: The amount sulphur and phosphorus bearing im- purities normally present welding urable effect the fissure-formation tendency; all the same, advisable use gases which are pure pos- Autogene operation another, from one type conveyer fixture another, swing post cranes with electric hoists are used. The temporary nose plug has ring and this, together with the lugs, greatly facilitate han- dling. The last operation, performed roller table, replace the ring the tail with the tail plug and the bombs are loaded from there di- rectly into box cars for shipment. Needed for Welding Aircraft Steels sible. The presence between 0.05 per cent and 0.8 per cent hydrogen sulphide has effect, but 0.9 per cent and upwards has very detrimental effect. The presence 0.1 0.12 per cent phosphine the welding gases does not affect formation tendency. Phosphine and excess 0.8 per cent have very detrimental effect. | sts di- Are Sharp Cutting Edges Necessary Rough Cuts? ” answer “no” the question “are sharp cutting edges necessary roughing cuts?” have run across count- less cases failures roughing tools that were simply dubbing stoning off the cutting edge tool. Many op- erators felt that when stoned off the cutting edge the tool, the tool wouldn’t cut, but were much surprised see that this stoning off the edge didn’t interfere with the cutting edge the tool. Fig. shows the method stoning off the edge. the the edge and stone off land that the feed per rev. feed 0.060 in., you can stone land 0.009 0.015 wide without interfering with the cutting action the tool. believe the reason why most persons are reluctant this because call tool taking This heavy metal removal not correctly interpreted. When tak- ing roughing cut the tool be- comes “wedging tool” shown Fig. The metal wedged off from the work forming little triangular section which filled with metal from the work Method stoning off the sharp edge lathe roughing tool. Built-up Roughing 2—The presence the edge gives the roughing tool wedge action rather than cutting action. The chip im- pinges the tool appreciable distance from the cutting edge. The author expresses the view, shared increas- ingly large number shop men, that stoning off the edge roughing tools actually increases the life between grinds. LEO ST. CLAIR President, General Tool Die Co. the “built-up edge.” The cutting edge itself serves useful func- tion rough cuts and when left sharp, several things can hap- pen that may cause early failure the tool. the metal being removed was absolutely uniform hardness would not experience trouble. But know have hard inclu- sions contend with. also know that when very hard metal off like soft metal. This hard inclusion therefore must touch the sharp cutting edge and then this hard inclusion com- pressed out the way. the meantime the hard inclusion will break out section the cutting edge resulting minute chipping. This action repeated and time the original sharp cutting edge be- comes series broken out sec- tions resulting bad loss clearance and failure the tool. This shown Fig. There may also chipping due the intermittent displacement the built-up edge. This metal welded the cutting edge area like smear metal and when displaced, probable that picks off small pieces the cut- ting edge also. stoning off the edge, you greatly increase the strength the cutting edge area, shown Fig. You can easily appre- ciate the great increase strength the cutting edge area caused stoning the sharp edge off. Then when hard inclusions touch this area, they are compressed into the softer metal and are carried away without breaking out the hard cut- ting tool material. also believe that when the built-up edge displaced, the chances having the hard cutting tool material “nicked” out greatly reduced. The importance stoning off the edge cutting tools roughing cuts increases with the non-ferrous cast alloy tools such Stellite, Rexalloy, Speedaloy and Kutkost and also all ce- mented carbide tools because the edge strength such tools not great with high speed steel tools. have already found out that some H.S.S. tools hardened Rockwell fail due ex- cessive chipping roughing cut unless the edge off. Many persons believe the only re- course have such tool made with Rockwell 60-62 This means shorter life due softer tool. stoning off the original tool edge, harder, more abrasive resistant tool can used and much greater life be- tween grinds can secured. The stoning off the cutting edge great importance rough interrupted cuts also. spots the built-up edge, they chips from the sharp cutting edge, shown form this enlarged view. cutting has included angle included angles 4—By dubbing off the edge rough- ing tool, the included angle the new edges becomes much greater, thus strengthen- ing the tool. THE IRON AGE, February 1943—55 ° ° ° i 4 | | | | 4 i | pe Store angle > 4 \ \ \ | ‘en i \ nt | tal Chi 1s contact f a & | Electric Arc Hot Topping The use feeding heads hot tops ingots and castings palliative that makes possible obtain certain amount sound metal the cost scrapping electric arc the ingot hot top offers possible means increasing net output and reducing cost, particularly alloy steels. rials, every might further the war effort saving time and materials being exploited the utmost. One such method which was developed many years ago the Huntington works the International Nickel Co., Inc., has been receiving con- siderable attention lately. Electric arc heating ingot feeding heads hot tops was de- veloped International Nickel Huntington, Va., several years prior 1924 and practical applica- tion started 1924. With minor modifications, all which have tended speed operations, the company still using the process today. Meanwhile, this technique has been successfully applied the United States the casting al- loy steel rolls and regular use plant the Pittsburgh area especially. has also been used successfully for some Austria, Germany, Belgium, France and England both ingots and castings. Express purpose applying the electric arc the hot top re- tard cooling this area, thereby eliminating minimizing top shrinkage due piping the metal freezes. Results indicate that this method increases the percentage good these days critical mate- 56—THE IRON AGE, February 1943 metal obtained the ingot which represents increase produc- tion since the time lost rework- ing the scrap eliminated. the case International Nickel has been found that the use the elec- tric ingot feeding heads has, the last analysis, given them five ingots metal out given heat where previously four tained. Certain minor difficulties, for the time being, tend prevent the ap- plication this process the in- gots standard steel heat but its decrease piping well carbon and sulphur segregation should important heavy ingots and castings where large sink-heads are necessary. probable also that the process can adapted special alloy steels where the sav- ings the metal, well the subsequent handling the ingots outweigh the detail and necessary costs for installing such process. Non-Ferrous Practice International Nickel’s Hunt- ington plant ingots Monel metal, nickel, other high nickel iron alloys are poured pit, big end up, average temperature 2750 deg. 1800 kva. trans- former supplies current six more electrode trucks which serve the various ingots. These trucks, which are moved around the in- GEORGE SULLIVAN got being poured, support elec- trode which adjusted over the ingot top. The electrode truck connected bus bar located the trough near the pouring pit; the current returns through steel wedge driven between the ingot mold and live steel rail running around the edge the pit. While single electric arcing units are used most ingots, very large ingots are taken care using more than one unit. The company has used many three some their larger jobs. Typical the technique the pouring 7200-lb. nickel ingot into mold, from small open hearth furnace tapped 2900 deg. The ingot hot top, made ganister and clay, about in. deep. The ingot poured through 1-in. nozzle and the mold filled quite slowly until there about in. metal the hot top. slag consisting glass and lime then thrown the metal the hot top and its cover placed posi- tion. The truck bearing the elec- trode with its regulating mechan- ism wheeled and set posi- tion that the electrode centered over the hole the hot top cover. The power turned and the electrode lowered until contacts the slag, after which the arc maintained automatically. Current input during the melting down pe- riod about 3000 amp. 115 volts and the time required melt the slag about min. When this molten the power reduced about 200 amp. and held for ap- proximately min. After shutting off the power, the electrode re- moved and the top closed con- serve heat. Sometimes the amount metal left the ingot hot top only in. Even this small amount hot top usually contains good deal usable metal. The use | ° ° ° ABOVE square blooms from same heat, showing the left untreated and the right treated bloom. RIGHT 2—The square blooms Fig. indicating here the analyses various electrically heated hot tops has cut crop loss this plant from per cent down per cent. Electrode consumption the neighborhood oz. per ton. 3-in. graphite electrode used for 3300-lb. ingots and 4-in. one for the ingots. The metals which the hot top process used International Nickel freeze without marked seg- regation since they are either the practically pure metal, nickel, the solid solution alloy, Monel. Unfor- tunately, killed steels not solidify without segregation. Instead, the last metal freeze very much en- riched carbon and the ingot must wo > a Wo 0.045 0.040 0.022 0.27 THE IRON AGE, February 1943—57 0.044 0.053 0.022 0.026 0.22 0.22 0.26 0.029 0.024 0.049 0.024 0.23 Seal 0.23 1.32 0.044 1S 0.021 0.26 0.95 0.047 its ge 0.96 0.27 0.26 0.26 0.046 0.019 0.022 0.26 0.27 0.28 0.96 1.12 0.040 0.055 0.019 0.030 0.28 0.29 e- 0.89 2.04 1.86 0.040 0.039 0.022 0.26 0.044 0.022 0.021 0.27 0.26 cropped, not only remove the pipe which reduced use the hot top, but also remove the seg- regated portion. Complete avoid- ance piping use the arc would not eliminate the necessity cropping slightly remove the segregate. This segregation fully discussed several reports the Committee Steel Ingots the British Iron Steel Institute, and given that institute’s Journal.* No. pp. 39-151; 1928 No. pp. 401-545; 1929, No. pp. 305-376. Also the separately printed 4th report 1932, 267 pages. Successful Europe Reports from that this process has been put into successful operation steel mills. states that has been used 100- ton forging ingots well castings and 200-lb. tool steel ingots. The author claims that pip- ing completely eliminated and segregation noticeably diminished. The quality the metal im- proved, adds, due the tranquil fusion the steel and the action the are and the flux. The type flux used not given. Leopold Granger, Revue Me- tallurgie, No. 1936, page 243. The Schoeller-Bleckmann Steel Works, Ternits, Austria, has suc- cessfully applied the electric hot top forging ingots ranging size rather complete report prepared engineer this plant, good results can obtained certain conditions are observed. These re- sults, based typical ingot, show carbon increase only 0.05 per cent the upper central portion the ingot head, elimination pip- ing and segregation man- ganese silicon. Sulphur content was 0.010 the center the ingot head but phosphorus was practically unchanged. Careful tests the portion the ingot below the ingot head the well Along the edges small remainders the L-segregation remained, but they give trouble the further working the steel. These results are apparently bet- ter than anything secured this country steel, ingots, but they demand the maintenance set specified conditions, the most im- 58—THE IRON AGE, February 1943 ; q 3 q iG. 3—Etch tests and sulphur points from the 13-in. square blooms, un- treated and treated. portant which that ingot di- ameter shall equal half its length. Other requirements, not difficult control, include careful regulation the heating time and the period after heating before removal the ingot from the mold. Current Consumption Schoeller-Bleckmann graphite electrodes which are con- sumed the comparatively high Current consumption between and kw-hr. per ton ingot. This compares with French figure less than kw-hr. per ton ingot and less than kw-hr. for each ton casting treated. Steel in- gots have been treated this coun- try with current consumption less than kw-hr. per ton ingot, though International Nickel the figure closer kw-hr. Some years ago the Electrode Di- vision the National Carbon Co., Inc., cooperation with the Union Carbide Carbon Research Labora- tories began series experiments determine the possibilities ap- plying electric arc hot tops steel ingots. The equipment available limited the application the process 8-in. sq. ingots. trodes in. diameter were used three treatments and in. the others. and preformed silica lime slags were used. The electrode consumption was the rate oz. per ton ingot and the power consumption kw-hr. per ton ingot. ac- count the small amount elec- trode consumed the arc the treat- ment was practically self-regulatory once the slag bath was melted top the ingot. The current was reduced from 1000 about 200 amp. once the slag bath was molten. the case low-carbon, low- alloy steels was possible work the entire ingot without cropping account splitting. With stain- less steels the flat upper surface the ingot opened slightly during forging, but the amount cropping necessary remove the split por- tion was less than per cent. Mill Tests The results these tests were encouraging that was decided give the process mill test larger ingots the plant Eastern steel producer. Ingots from several heats were treated (using standard clay hot tops) and compared with standard ingots. One these was per cent carbon-manganese-molybdenum steel, cast 24-in. round corru- gated surface ingot mold with the big end up. The ingot weighed about 8000 and the hot top was approximately in. diameter. The slag consisted lb. mixture two parts silica and one part lime. this case the surface the steel had frozen before the power was applied due blown fuse. Sounding tests showed that the steel was molten the bottom the hot top when the current was turned off, which was hr. and min. after pouring. hr. and min. all metal the hot top had frozen, and the slag froze the end hr. and min. When this ingot was stripped and the hot top cleaned off, the surface was found perfectly This ingot and untreated ingot from the same heat were rolled * q 3 3 down 13-in. sq. blooms. Fig. shows the manner which the blooms were sectioned, and Fig. indicates the analysis various points, secured borings. The etch tests and sulphur Fig. represent the top per cent the ingots after rolling blooms. All the metal below the hot top the electrically heated ingot was sound and more solid than the metal the middle the length the bloom. The comparison ingot showed blowholes for length more than foot below the bottom the hot top. will noted that there was deep piping sulphur segregation the treated ingot. Some midway segregation appears this ingot, but the cen- ter checks are fairly uniform. There was, however, considerable loss manganese. Sulphur and silicon analyses are uniform but there was more phosphorus segrega- tion than was found the stand- ard ingot. Another heat that was treated the electric arc method was 1.4 per cent carbon-manganese-molyb- denum steel. The mold this case was rectangular, measuring in. The lateral dimensions the hot top were approximately in. The same slag was used be- 4—13-in. square blooms, untreated and treated. ¥ 4 fore. Treatment was started imme- diately after pouring and continued for hr. The mold top remained open and the electrode was moved over the surface. Settling the surface was uniform and without piping. Treated from this heat were also rolled 13-in. sq. blooms. These sections are pictured Fig. and their analyses Fig. The heating was not effective this ingot. The pipe extends down into the ingot, though not quite far the standard ingot. The sulphur prints, Fig. and analyses indicate much better distribution the treated Some negative carbon seg- regation present the top the treated ingot compared heavy positive segregation the standard ingot. Here again there was considerable loss man- con loss. Phosphorus checks show difference between the two in- gots. The results these tests were satisfactory every way except for the negative segregation car- bon, manganese and silicon the upper third the ingots. This FIG. 5—Analyses the square blooms untreated and treated. 0.2) THE IRON AGE, February Co., | ion Ya- nts ap- teel ted lec- the and ere ion ion ac- lec- ory 200 ork 0.22 0.012 0.012 0.013 0.22 0.21 0024 0.01 0.015 0.20 018 the 023 0.23 @135 was 0.22 had 0.018 0.23 0.20 0.013 the 0.019 this top < ty : » & was due the siliceous slag used the treatment and can avoided the necessary adjustment. was not expected that this would cause trouble, for the early experi- ments were directed determining electrode size, current requirements and heating times necessary re- duce eliminate top shrinkage due piping. Treatment Rolls the application the electric arc heating large roll castings, the conditions are especially favor- able, since the castings are large, the number treating equipment units small, and the castings are made dry sand molds which pro- vide fairly good heat insulation around the risers that the power required low. The treatment pe- riod required, however, long comparison with chill-cast ingots, account the large mass metal the casting and the rela- tively low rate heat loss. The first application for this pur- pose was made foundry near Pittsburgh, whose specialty was the casting large rolls for rolling mills. the conventional practice before the installation the elec- trode treatment, the weight the riser was equal about two-thirds the weight the roll. The rolls IRON AGE, February 1943 Secondary voltage (about Current 800 amperes approx. Electrode Molding san LEFT 6—Sulphur prints from ABOVE Mold 7—This shows the electrical connections and mechanical ar- rangements for treating roll cast- ing hot tops. the case ingot casting iron molds, the connec- tion for the return circuit simple contact need only made with the lower part the mold. were cast end circular flask, bottom-poured through sprue until the level the metal the mold was above the roll proper, and the balance the metal was poured directly into the riser. When the electrode treatment was applied, dome-shaped roof molding sand with hole the center for the passage the elec- trode, was rammed circular flask and dried core oven. soon the pouring was finished, flat iron bar was thrust into the molten metal the sprue form one side the electrical circuit. The necessary slag was then placed top the molten steel the riser, and the dome roof placed top the flask. The electrode rig- ging was set top the mold, the electrode lowered through the hole the roof, and the are struck and maintained automatically until all the metal the casting had solidified. (See Fig. 7). The heat supplied was sufficient maintain molten the entire surface the metal the riser, and the shrinkage the metal the cast- ing took place due solidification, the molten metal from the riser flowed into the casting replace the shrinkage and the surface the metal the riser dropped uni- formly. After the casting was en- tirely solid, the power was turned off and the metal remaining the riser allowed solidify, which did without piping and with flat top the riser. The first tests were made with normal-sized riser order test the performance the equip- ment. When this was found satis- factory, the size the riser was gradually. reduced until was cut about half the original vol- ume. not certain that this the maximum possible reduction but the volume metal has been kept this point absolutely cer- tain that there will pipe unsound metal the roll casting. This reduction the volume the riser has considerably increased the output capacity the foundry and has also made possible cast larger rolls than previously, the total amount metal available for single roll was limited the capacity the open-hearth fur- naces, and the electrode treatment increased the metal usable the roll casting from per cent the total melting capacity. specific example the re- sults obtained, certain roll cast- ing according normal practice, was in. diameter 133 in. long and weighed 47,500 while the riser was in. diameter in. long and weighed 29,800 the roll. using the electrode treatment the weight the riser was reduced 14,800 Ib. per cent the weight the roll. This riser was sectioned and about two- thirds was perfectly sound steel without any indication porosity, that the weight the riser could have been still further reduced. The power consumption has averaged about per ton metal poured. Electrode con- sumption ranges near per ton metal. The process has now been use this foundry for three years, and the average saving metal has been 4.5 tons per roll casting. / 4 ' => r= Electrode sani Slag Casting Mold was cut nal vol- this tion but kept ely cer- pipe casting. the icreased foundry sible the the per cent the re- practice, 133 in. b., while diameter 29,800 veight electrode the riser per roll. 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Protektol supplied liquid form ready for use, but special re- ducers are available adjust vis- suit variable conditions and equipment. may applied brushing, spraying, dipping roller-coating. Applied normal thickness and under normal conditions temperature and hu- midity, Protektol will dry touch min. and will strip min., desired. minimum film thickness 0.001 in. must used provide sufficient tensile strength for re- moval. cases where sheets must stacked shortly after removal from the spray booth, application little heat desirable prevent solvent trapping and subsequent softness film and low tensile strength. Hot air from either just outside the spray booth, has been found yield satis- factorily dry films. Air 150 deg. peratures for shorter times effec- tive. bank infra-red lamps available, can used mate- rially shorten the drying time. Brushed roller-coated films, be- cause the more slowly evap- orating solvent employed, require longer drying periods. Running knife blade other sharp object along the edges break the film the points where the highest surface tension de- veloped usually permits removal Protektol single sheet. faster method removal puncture the film the center with pin ABOVE simplest means removing Pro- tektol lift one edge and peel off the metal sheet. Running knife blade other sharp object along the edges break the film the points where the highest surface tension de- veloped facilitates removal. RIGHT NOTHER method removing the film lift one corner and apply air from jet. and apply jet high-pressure air the hole. The film swells like balloon, finally breaking and fly- ing off the surface. The balance the film may then removed directing the jet air underneath the exposed edges and blowing off. Drawing layout work may done right the film using