The Iron Age 1943-03-04: Vol 151 Iss 9

MARCH fast WAR SERVICE BRINGS OUT EXTRA CAPACITY general superintendent plant now war work remarked one our representatives: “This war effort has given real chance learn about the production rates our machine tools. Now, with the close tolerances and fast production demanded the various governmental agencies, find that Warner Swasey stands out head and shoulders our turret lathe Yes, under war pressure thousands Warner Swasey turret lathes are being worked con- tinuously, hours day, month after month, without breakdown time out for repairs. this emergency high speed production precision work, Warner Swaseys are given full opportunity proving they can turn metal better—and faster. om, And when war against the Axis ceases, there will another war against unemployment, lower standards living, and enormous per capita debt,—another “war” which can only won production! that period will our challenge design and build turret lathes that will out-produce the turret lathes that today seem the last word. MARCH 1943 VAN DEVENTER President and Editor BAUR Vice-President and General Manager Associate News Editor, JAMES Associate Editors Editorial Assistants BUTTERS Resident District Editors Washington Pittsburgh Washington Chicago Cleveland Detroit QSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP McCUNE Milwaukee Birmingham Toronto, Ontario St. Louis BACON Seattle DIX, Manager, Reader Service Advertising Staff Blair, 621 Union Bldg., Cleveland Herman, Chilton Bldg., Philadelphia Hottenstein, Otis Bldg., Chicago Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, 100 East 42nd St., New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York Fitzgerald, 428 Park Bldg., Pittsburgh Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout. Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub every Thursday. Subscription Price North America, South America Possessions, Foreign, year. Single Copy, cents, Annual Number, ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Editorial and Advertising Offices 100 East 42nd St. New York, U.S.A. Executive Offices and Sts. Philadelphia, Pa. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President HILDRETH, GRIFFITHS, Vice-President Vice-President Vice-President Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, CHARLES HEALE DUFFY This Week Editorial Door Openers for State Socialism Technical Articles Steel Laggard? Finishing Metals Band Filing Training Program Aid for Industry Features Assembly Line Washington Fatigue Cracks Dear Editor News and Markets This Industrial Week Personals and Obituaries 160 Machine Tool Activity 162 Non-Ferrous Metals 164 Scrap 166 Iron and Steel Scrap 168 170 ° ° Index Advertisers 261 Copyright, 1943, Chilton Company — 4 | 3 4 q A | ° q } | | | | | > f | | i] 4 ay , | 1 Unusual work like this massive Drilling and Tapping Ma- chine Base demonstrates Mahon welding skill. New Welded Steel Plate Products Now Are Fabricated Mahon addition welded steel machine bases, Mahon welding skill being utilized for the fabrication many new and different products. Gun mounts, furnace casings, engine frames and crankcases, pump supports, electrical, gas and hydraulic equipment, comprise but few many items that Mahon facilities are called upon produce. Let look over blueprints your requirements. Regardless size shape purpose—if they can practically and economically fabricated from steel plate—we will advise you. Quotations will promptly supplied. DETROIT Fabricators Machine Bases and Frames and Many Other | Door Openers for State Socialism the common purposes which capital, labor and manage- ment can unite assure the survival the principle growth. Nature fashioned that principle and applied all living things. Nature believes small beginnings. The whale, the elephant and the redwood tree well men and women were not summoned into being full grown. They started small and they successfully met the require- ments environment, they gradually grew full stature. Men have long applied this principle growth business and industry. has been most successfully applied our own country which now has over 2,000,000 individual going concerns. Some these employ many 100,000 people, but all them started small. Manufacturing plants, like plants the vegetable kingdom, not last forever. successful country must have new crops them coming along and must also provide atmosphere conducive their growth. New plants and new business concerns with opportunity for growth spell employment, more and better wages, profits, better living and flourishing trade. These things are good for everybody. particular, has been land opportunity for growth. For opportunity for the man with idea but little money establish MARCH 1943 business. Henry Ford example that, but only one many. There was toolmaker working for Ford some years ago, for example, who kept his eyes open and his brain busy. conceived ESTABLISHED 1855 the idea that many the special tools and dies used making auto- mobiles could made specialized tool and die shop and sold the automobile makers profit, yet less than the cost make plant where-toolmaking was only side line. Private savings, willing take chance, helped this man carry out his idea. Today head one the most successful tool, die and machine tool plants the world and employs thousands. there had been twenty-five thousand dollar limit private earnings those days, the private savings would not have been avail- able finance this man’s idea. And had gone Washington the money from alphabetical agency they would have either turned down his modest requirements loaned him ten million dollars, either which would have been fatal. are have multitude little business and industrial seeds planted assure future harvests employment and wages, must preserve the opportunity for private investments. Labor has the ize biggest stake this preservation. can well afford fight, with capital and management, the half-baked schemes disguised war measures which are actually door openers for state socialism and state ownership. i AG | | | | | Dearborn From Automobiles Tanks and Back Automobiles Throughout the years before Pearl Harbor, Inland supplied great quantities many kinds and forms steel the automotive industry. When manufacturer wanted steel special form, finish, analysis, Inland research and mill men supplied those wants. Often original work our research staff developed new steels, which were used build better auto- mobiles. Inland grew with the automotive in- dustry and that industry grew with Inland. When war came America, Inland was pre- SHEETS STRIP TIN PLATE STRUCTURALS PILING RAILS py WY 4 Street, pared, with skilled men and modern equip- ment, supply vital part the steel needs the automotive industry, converted 100% the production army trucks, tanks, jeeps, shell, and many other kinds war equipment. Now the past, Inland metallurgists and mill men are making new and better steels steels that give our fighting men the advan- that will help build better auto- mobiles when our enemies have met the terms surrender.” BARS PLATES FLOOR PLATE TRACK ACCESSORIES REINFORCING BARS Uy Yj, tt Wa yy, _ field the of { ling cuss thes as hith are croa dom tren thy Wit! Wise how hew bein time tons SITUATION developing the utilization materials which those who are interested the post-war fortunes the rolled steel industry need examine closely. The pace shifting technology becoming very swift. rolled steel —an old and distinguished contender —getting trim hold its own, not say forge ahead, the face group impressive newcomers the field structural materials? the industry doesn’t gird its loins for the coming battle won’t for lack because truly start- ling predictions are being made con- cerning aluminum, magnesium, ply- wood and the plastics, their mounting output, wider applicability and much lower selling prices. The references made this dis- cussion the improved properties these new materials, now looming serious contenders for markets hitherto held securely rolled steel, are way posing the problem which the steel industry must solve would ward off many costly en- croachments and hope maintain dominating position the world-wide towards lighter and more effi- cient structures. The writer’s sympa- thy and confidence reside with the steel industry and none could hope more than that the job hand will tackled and thoroughly disposed of. With this purpose mind seems wise review the disturbing claims how being made quite openly steel’s competition. annual productive capacity being created for more than one mil- lion tons aluminum, total six that existing 1940. this capacity some part 500,000 may dismantled when the war because cost level regarded economy. However, producing facilities, once created, have way FREDERICK FOOTE President, Alloys Development Corp., Pittsburgh the light metals and plywood are all energetically challenging rolled dominance the post-war “materials Will the steel industry capitulate can protect its mar- kets even invade hitherto ignored markets. That the theme which the author, well-known steel executive, develops herein. holding for one reason an- other; but, assuming that such will not prove the case this instance, there will still remain equivalent three times the largest pre-war output, and with much lower selling price. This quantity aluminum would more than ade- quate build new each year many railroad passenger cars are now being operated America. claimed that the use aluminum and transparent plastics will reduce the weight the post-war auto about one-half. This disturbing thought because, should happen, steel structural material could largely eliminated from the pleasure car. doubt would remain the heavier commercial vehicles. Aluminum Something like per cent steel production has been consumed this industry recent years, and per cent the total went into pleasure car construction. Come peace, few doubt that motor cars will again “sell like any wonder that the steel industry’s mouth waters when considers that x-millions cars times y-tons per car promises huge post-war market? motor car design should remain static wish- ful thinking indicates, this equation would hold, but the aluminum inter- ests seem have disposed such thinking with one stroke. They are working 24-hr. day, seven days per week, win the war, but they nevertheless, “eighth” day devote “imagineer- ing.” Imagineering—a synthetic word newly coined them describe highly productive activity involving combination metallurgy, engineer- ing, and imagination applied the ucts and uses absorb their greatly increased output. result this they would use 500 aluminum reduce the weight the post-war auto 1000 lb. Whether they can achieve this objective re- mains seen, because one cannot help but feel that the rolled steel in- dustry will undertake some “imagin- its own account prevent it. The industry can count period grace which build its de- fenses, judging from recent statements leading thinkers the automotive industry that there will time before the war ends tool for the “dream” car the future. They say that the public can expect little improvement its post-war pleasure car over the familiar 1942 models. But according Dr. Chas. Stine, vice-president duPont, this period likely very short duration. Said the recent con- vention the American Chemical Society: “Fuels and metals and plas- tics are now ready complete the revolution transportation, begun early the century. The automobile manufacturers’ slate has been wiped clean for fresh start, which should THE IRON AGE, March 4 iy NY. A | 7 | =, q | ‘ N 3 ansas result new cars that will incredible efficiency, judged present standards. Since motor car produc- tion stopped, the shiny new models that are now gathering dealers’ storerooms have aged, tech- nically, least two decades. are now the 1960’s motor cars measured the old pace develop- what they are now, power will up, and fuels may yield miles the gallon better.” similar story the making with respect magnesium. The war output this light metal, lately regarded something novelty, will rate more than double that aluminum 1939. There are difficulties overcome the fab- rication magnesium, but they will probably met successfully the course time, and—as things these days—a very short time, doubt. Already the price level has been reduced point where about par with aluminum its strength weight ratio and with de- cided edge considering stiffness factor. Keen competition sure develop between aluminum and mag- nesium, and this can scarcely help but make the going harder for steel. Plywood will make strong bid for many structural applications. The laminations wood, bonded resin, and the methods used its manu- facture and application, have im- proved plywood that now possesses and fact resents being designated plastic. Plywood very strong and light, does not splinter and inherently fire resistant. can now formed and fastened satisfactorily. When measured strength weight ratio and elastic stability, stands first the line structural ma- terials. Perhaps the predictions which are now being made for the place this material will command the struc- tural field are premature, but has made impressive beginning avia- tion, and also finding wide applica- tion the building industry, and for partitions ship construction. What About Plastics? The writer tosses his hand when comes the claims made for the future the plastics. All customary methods appraisal are confounded learning that weeds are potential source plastic. hay fever suf- ferer amusing contemplate whimsically that certain bath room fixtures might soon made best from ragweed; but perish the thought that this devilish weed might cultivated for such source material. After reading several articles the many plastics and learning the hundreds companies established recent years produce them, one brought the commercial branches the steel industry gets the notion that anything will make plas- tic that must reckoned with “even snakes and snails and puppy-dogs’ tails.” seems order stand for “look-see” this situation. Inroads Rolled Steel Substantial inroads have been made already upon rolled steel markets materials that are not new but which have kept well abreast progress the engineering world—indeed, have sometimes set the pace. Such the case cast steel, referred later this discussion. account what seems the offing, has occurred, opposite the great consuming markets for struc- tural rolled steel order this point. general relates struc- tures which are two classes, mobile and static. The former will con- sidered first. RICHENOUGH Bridge over Sabi River, Rhodesia, made high ten- sile steel fabricated Dorman Long Co., Ltd., England. span 1080 ft., this bridge was the third larg- est arch the world the time its construction. 50—THE IRON AGE, March 1943 recent years the largest ing market for rolled steel moving structures all kinds has been the automotive industry. Possible opments this field, which could dire consequences for steel, have been touched upon the foregoing and need not elaborated. The aviation industry challenges one’s powers imagination any. thing can happen here, but steel have battle its hands dominate any considerable part this market, There may substantial place the stainless types, and even some the high tensile types, but this not certain the moment. There price can paid for weight saving, hence the difference cost, wide may be, between the highest and lowest priced materials will not deter- mine their selection. general, the ratio and stiffness, stability, will the ciding factors. For this reason the light non-ferrous metals, plywood and plastics, groups not fear the petition steel aviation. But al- uminum, recently king, casting anxious eye both plywood the plastics. isn’t pleasant contemplate that rolled steel’s participation the aute motive market may whittled relatively small proportions, and that steel may find little place the enormously expanding demands aviation, but these conditions are not eventuate the pressing need for vigorous campaign the realm products research and development can hardly over-impressed those who shape the destinies the steel industry. The need pointed out high-ranking and commercial advisors been watching the significant events, but, far, joint try action has resulted, and advancement can noted only respect individual companies, cializing some particular phasized that this discussion structural materials only. Turning other markets, one more reason for optimism, but, much the opportunity will without full industry and “imagineering” There are still some the rolled industry who believe that the duction the weight-saving steels markets not seriously threatened other materials was mistake. base their objection upon the that advocate, deliberately, reduction the total tonnage mands the market. Aside sibi this ern ly, com Way are ies, cule; Inde they hene grow could Such x : wi su Se; «(OV pre tio rig i ° ° | ving the evel- have been and will for not -pound and deter- ‘al, the and the de- the and But al- casting ood and ate that and the ands are need for realm elopment the technical mare int indus only with one but, ill rolled the eatened take. the rately, from "Spirit built ond operated Australia. This crack train made en- tirely Corten steel, lightweight alloy combining great strength with siderable corrosion resistance. knowledge that sound progress never works out that way, there the plain fact that swift succession events the structural world has made such position untenable. The light weight development has become epi- search for the best possible products improve every type structure and thus hasten those existence over the brink obsolescence. Engi- neering plans and service should provided show the all round econo- mies using steel those applica- tions where can proven that rightfully belongs. examination the railroad market presents some interesting pos- sibilities. There little equipment this field which will not worn out obsolete when the war over. Mod- ernization will need proceed ly, meet the threat ever greater competition from the highways, air- Ways, waterways, pipe lines, and what hot. The magnificent job the carriers are doing the present emergency sound rebuke all former crit- ies. All agree, however, that they are into the bone and sinew their facilities perform the Her- culean tasks now imposed upon them. Indeed the excellence their accom- may prove serious obsta- tle because, having succeeded well, they may deemed invulnerable and henee denied the equipment and man- vital the discharge their wartime burdens. Should this and the railroad plant fail, prove fatal our whole war stroke bad management has already caught with Hitler, and that his neglect rail transportation may contribute heavily Germany’s downfall. The railroads constitute consum- ing market for rolled steel principally, and will undoubtedly continue so; however, there competition this field. For example, the cast steel industry has succeeded extracting and retaining upwards 500,000 tons business from this market annu- ally, which was formerly enjoyed rolled steel. This was accomplished patent pooling; joint research and products development within the in- dustry; the adoption standard spe- cifications; the maintenance uni- form quality; service prospective customers; joint adver- tising and sales promotion; and, lastly, adroit political maneuvers which resulted writing rolled steel out the picture some notable in- stances. The light non-ferrous metals have made some headway against steel passenger car construction. Plywood and the plastics have also put appearance but, from overall tonnage standpoint, these can hardly present because passenger car con- struction represents such part the demand for rolled steel. The big market railroad rolling stock lies the building freight cars and here steel well established. The ob- jectives, which call clearly for joint industry action this division the market, are, first, expand the de- mand for rolled steel through mea- sures which will hasten obsolescence, and, second, stem the encroach- ments competitive materials. That these objectives can achieved through industry promotion su- perior steels already demonstrat- fact, and that they cannot achieved otherwise equally demon- strable. Since 1935 there have been rail- road passenger cars street cars built America that did not embody “light weight” materials their de- sign. The high tensile steels and stainless account for approximately per cent the total, and aluminum for the balance. this period up- wards 50,000 modern lightweight freight cars every type, built high tensile steel, have been placed service and operated most profita- bly. These new cars render the old heavy equipment uneconomical operate and subject retirement. Nystrom, mechanical officer the Chicago, Milwaukee, St. Paul Pacific, article entitled “Why Lightweight Freight (Rail- way Age, November, 1938) said: “It the author’s conviction that some railroads rebuild cars give them heavy repairs when would more economical retire and replace them with new cars.” Not more than three four tons steel are required heavily repair steel freight car whereas minimum eighteen tons various steel products enter into the construction new car. Mr. Nystrom also stated that 2,000,000 new freight cars would needed the railroads over the next ten years, from 1938, and added: “The saving $60 per car per year which would THE IRON AGE, March * | iy result (from) reduced weight the scale previously given tons per car) applied the 2,000,000 cars built would amount $12,000,000 annually for each year the quota cars are service, and this saving will multiply new quotas cars are added each year, total saving ten years $660,000,000. build 2,000,000 freight cars cost of, say $2,000 each would involve out- lay $4,000,000,000, which would long way toward restoring employ- ment and prosperity.” Certainly the effects the war, which Mr. Nystrom did not anticipate 1938, should prove his estimate most conserva- tive one. The mutual benefits derived the rolled steel industry and the railroads from the weight-saving pos- sibilities the high tensile low alloy steels, used modern welded design, are the most promising any now predictable the post-war horizon either industry. For rolled steel, com- petition will defeated and new and more profitable markets created reason the obsolescence caused and the higher priced materials involved; for the railroads, means provided for lowering operating costs and for discouraging new competition well; for the nation, much greater employ- ment. Could anything more important the preservation the American system free enterprise, say nothing their ewn welfare, than that these two giants industry should add “eighth” day their work week, now, which plan their peace-time futures. Steel Shipbuilding The shipping industry constitutes another market which steel should dominate. Here, with the railroads, the competition new materials should disposed successfully. However, the Navy making good use aluminum for weight-saving purposes warship construction, also plywood finding its way into com- mercial vessels. Some these light materials are sure adopted but, ‘in this market, obsolescence once again that should provide the most promising growth demand for roll- steel. Germany, Great Britain, France and Holland have been using increasing tonnage high tensile steel ship construction over the past several years. The Europa, Bremen, Queen Mary, Queen Eliza- beth, Normandie and Champlain are known have used substantial quan- tities high tensile steels their designs. paper presented November last year the annual meeting 52—THE IRON AGE, March 1943 the Society Naval Architects and Marine Engineers, Edgar Trask the firm Gibbs Cox, explored the advantages using the high tensile steels ship construction. Taking oil tanker example the in- creased earnings possible weight reduction, Mr. Trask said, part: “The ship considered service be- tween New York and Port Arthur, Texas, distance 1875 miles. the sea speed knots, and the turn-arounds are made day each, the total time for the round trip will days. With allowance days for annual over- haul, there will be 25 round trips per year. The 380 tons extra deadweight in- creases the pay load 9500 tons per year, which for oil degrees Baumé 78,200 more barrels. carried per year. a freight rate of 23 cents per barrel, the added income per year would $10,000. What small cost there might han- dling the added cargo is neglected. “If the base labor cost per cent more than for mild steel, the added nual net income of the ship of high elastic steel over that of mild steel would be $11,800, which 32.4 per cent the estimated added first cost. the rate the same, the ship high elastic steel costs less and earns $19,800 more per year. further saving should effected the 100 per cent added durability the high elastic steel. the 20-year nor- mal life mild steel tanker, one major rebuild needed after years, none should needed that time for the ship high elastic steel. After years both ships would probably suffer from obsolescence. Assume the rebuilding the mild steel ship require sixteen weeks’ time and the replacing 800 tons steel cost $450,000. During this time eight round trips would lost and, the net carrying 128,000 barréls oil each voyage cents per barrel, the lost income and cost structural overhaul are about $532,000, $26,000 per year. This becomes gain for the ship high elastic steel. For the higher labor rate, this added annual net income would $38,400, about 1.54 per cent first cost $2,500,000. For labor rate the same for mild steel, the added annual net income would $46,- 400, 1.85 per cent the above cost. Thus, conservative basis, the substi- tution high elastic steel proposed should increase the earnings such tanker not less than 1.5 per cent each the years its normal life. the present annual net earnings are per cent the valuation, the substitu- tion high elastic steel would produce per cent greater earnings. “About per cent this addition income may attributed the superior corrosion resistance expected and per material.” Mr. Trask indicated that similar re- sults could shown connection with ocean liners. There are many other types mo- bile structures which provide excellent opportunities for market expansion through the use high tensiles modern lightweight design. few which have been tested years service are: Mine-cars, dump cars, trailers, tank trucks, buses, street cars, elevated and subway cars, tainter gates for river dams, pon- toons, dredges, barges, portable bridges, ete. all instances the econ- omies effected are impressive and should cause degree obsolescence that will result many profitable re- placements. Now, turning the field static structures, interesting find that Great Britain, France, Germany, and India are more advanced the use high tensile steels for weight- saving purposes than America. port No. 501 the Materials Commit- tee the German Iron and Steel stitute, June, 1940, said: “In bridge and building construction they have been very conservative Amer- ica and still adhere riveting. For this the engineer himself responsi- ble. Although proposals for weld- ing building structures appear and there, general application welding for improvement structures takes place. ... the end 1938 the entire United States ap- proximately three structures were welded, whereas Europe the number bridges alone eight hundred.” “It appears that steels has followed different path America from that Europe. The German steels were developed meet the requirements bridge and building construction, and from there, .found their way into tion.” The economies the development, they relate static structures, are most promising, but less easy set forth general terms. special analysis must usually made each individual project, and all cost fae- tors carefully weighed determine the manner which steels may used the greatest ad- vantage. One the chief considera- tions the delivery cost the com- ponents the point These costs vary with the distance covered and the transportation facili- ties available. Referring the French paper, “La Revue May, 1935, the following quoted: “The suspension bridge Mananjary (Madagascar) would weigh 470 tons ordinary steel. The use chrome-copper steel (high tensile) reduced the weight 335 tons, saving 28.7 per cent. Transportation materials very expensive, especially the Colonies: freight Colonial port, Colonial railway, and sometimes reduce the weight, even the steel costs more.” Elsewhere said: “In the case electric mission towers the economy weight realized the use high tensile steels great importance the towers are installed the try and some them are located distant and inaccessible points. the decrease weight reduces the installation cost greatly.” ter the hai por con ere — ny, the rht- Re- mit- In- idge they ner- For veld- here such end ap- alone ached that ength ath The and there, pment, es, are set special each ermine uperior est ad- These “La the gascar) steel eight yer cent. very the steel report weight tensile the ocated ts. Henee the The author has record twenty- two the many bridges built vari- ous foreign countries high tensile steels. Some these were erected home and some shipped distant points. Ten the number are Ger- man manufacture and were erected there, three were China, two Denmark, two India, two Africa, one Sweden, one France, i wae and future business men have re- turned employment. This new incentive broaden export markets should prove one the tangi- ble results the globe-trotting neces- sities this country’s war effort. view the head start that foreign competition has gained the use better steels improved struc- tures, rolled steel the United States framework this skyscraper Shanghai high strength German struc- tural steel 52. The spires are about 270 ft. above This building was erected Dortmunder Union Construction Co. and one Australia. The saving over ordinary steel ranged from per cent. One these, the Bridge, erected India, employed 17,000 tons “Tischrome,” chromium-copper high tensile steel manufactured the Tata Iron Steel Co. example the use high ten- sile steel building construction the Hongkong-Shanghai Bank. Shang- China, the tallest structure Asia (if still standing), built the Dortmunder Union Bridge Works Germany, and erected Shanghai. The saving weight was approxi- mately per cent. That these weight reductions repre- substantial savings erection costs, ocean freight, and other trans- portation charges, obvious. reasonable assume that the American steel industry will wish for such structures, remote parts the “new” when the war over and America’s world-conscious engineers will need muster every bit its technical and commercial ingenuity obtain its proportionate share the business offered. Ocean freights are likely determining factor, especially the markets the East, and these that the greatest promise seems lie. contemplate the possibilities China alone causes one take deep breath. The world becoming “lightweight- minded” with startling rapidity. The trend was clear long before the war, and now unmistakable. Maneuvera- bility and speed, coupled with high degree stamina, are qualities de- manded structures for all mechan- ized warfare, land and sea, am- phibious, and the air. War de- mands and the necessity utilizing every material means best satisfy them have been powerful challenge the ingenuity chemists and en- gineers everywhere, and the success with which they are meeting the chal- lenge promises something akin novel world when peace comes. These wartime “musts” have also resulted the creation capacities for scores new materials scale that was beyond the comprehension anyone only short time ago. wear and tear that creates re- curring business. Obsolescence creates new business and new industries. New industries seldom create ness; instead they displace old indus- tries, thus the motor car displaced the carriage—and the bus, the street car. What the impact the aviation in- dustry will all other forms transportation yet determined, There only much real wealth, consequently only much depth the average man’s pocketbook. can have more things, higher mate- rial standard living, only when greater production and lower costs place them within the depth his pocketbook. Inventive genius creates the new things which render the old obsolete. Enterprise and the profit motive put them into production, and the insatiable desire man for every- thing new and shiny which can afford creates the demand. The lower- ing selling prices, the cheapness with which industry can produce more things determines the velocity the “turnover” business. This pre- cisely the objective and effect the lightweight development the struc- tural world today. The lightweight development, adopted program, would mean the steel industry what improved and lower priced models mean perpetually the automobile, radio, refrigerator, and score other industries. What adds to, simple terms, modern merchan- dising. the face all this, the light- weight development hinged upon the so-called low alloy high tensile steels, demonstrated successfully the world over for more than decade, remains drifting, haphazard movement with- the rolled steel industry. has now reached the age ten and still orphan, not recognized the in- dustry’s own fair-haired child. would seem high time that the group the industry, and comprehensive plans for their post-war application formu- lated. emphasized that steel’s job winning the war; true, but job No. preparation for the peace, be- gun now, certainly its Siamese twin. “Yet here, abroad, abroad, for shame! The wind sits the shoulder your sail.” THE IRON AGE, March n | | HERE are thousands delicate filing operations that always have been and always will done manually. There are also count- less numbers applications for jig filing the method that reproduces the hand stroke mechanically. Contin- uous band filing procedure, how- ever, the most productive the long run due the absence non- productive return strokes. other words, file band actually cuts sec. per min. File bands were accepted very promising and practical almost years ago, but for some reason other their general economy was not realized until low-cost rigid band was developed. the other hand, the introduction specialized 54—THE IRON AGE, March 1943 band sawing contour sawing ma- chines really revived band filing this last decade. The war emergency has truly placed band filing machines the high production metal working equipment bracket. Contour sawing machines are read- ily converted band filing. However, the regular band filing unit, being moderate cost, the best invest- ment conditions demand that the productive capacity the contour sawing machine not interrupted. Modern file bands consist pre- determined number file segments in. long mounted band high grade spring steel having maximum strength and resiliency. File bands produced today will not stretch, but the tension should nevertheless re- LEFT band filing three open- ings machine part 0.00! in. perpen- dicular and spacing accuracy. (Insert) Close-up three- dimensional band fil- ing operation formed tool, showing saw (right) and file used. RIGHT 2—Macropho- tograph me- dium bastard file seqment. moved when they are not use. File segments are manufactured and in. widths. Twenty dif- ferent styles simplify the matter applying the proper technique. Flat, oval and half-round choosing file that will give the max- imum cutting surface for the outline finished. Average Life 100 Hr. Since modern file bands have cut- ting life not less than 100 hr., they tifically selected material, workmanship, constant inspection and research. All the must carried through from raw stock finished product close degree uniformity main- nes tained. gla One should bear mind that the teeth file band action are quite small chip curls before each the tooth points and dropped when clear a Band Filing... dif- ‘lat, rmit cut- they cien- and sities raw close main- the quite the clear the work and the segment con- taining that particular tooth circles around for the next “bite”. file band has such cutting prop- erties that will even “saw” deemed necessary. %-in. band, for instance, would leave four times wider than the average saw band, but this file band would pro- duce oz. tool steel filings hr., almost ten times that hand file. Much the same with saw band, heat has profound effect file band and also the surface being filed. Clean cutting therefore essential because the heat produced ef- ficient file even for short period will surely destroy its remaining effective- ness. heated surface soon becomes glazed and the material becomes impregnable any heated, chip- crowded teeth finishirg fine- tooth file. the other hand, coarse medium coarse will readily cut ABOVE 4—File bands are real production tools. this case the former cost producing these sheet metal parts has been reduced per cent. ° RIGHT Fis. 3—View showing how band rigidly supported for maximum filing feed. ° CHAMBERLAND Continental Machines, Inc. Files all types are important war production drills, reamers, taps and milling cutters. Machine filing with band type files putting this class work more and more into production opera- tions. The author brings this subject date and includes data new type short angle file developed for non-ferrous materials. identical material with minimum amount heat being generated. Excessive work pressure feed has not the serious effects with band filing has with band sawing. With band filing, any amount pressure can exerted, even the point stalling the band. This practice does not any means mean faster filing. The correct pressure one that will just about produce that “biting” effect. More pressure will impair cutting ac- tion and too little pressure hard the fine edges. Three Available File bands are available three distinct “cuts” and each has very definite purpose application. The bastard cut file the most commonly used since adapted for general use all steels and most metals. This file made with 12, 14, 16, 20, and teeth per in. the case saw, the spacing teeth file determines its production rate and surface The coarse grades include files with 12, and teeth per in. 12- tooth file termed extra coarse, the 14-tooth coarse and 16-tooth me- dium coarse. All three are recom- mended for general use steel where cutting rate rather than finish the chief objective. The 12-tooth bastard cut file also performs exceptionally well cast iron. The 16-tooth file good choice for good finish mild steel, light pressure giving still better finish. The 20-tooth file best for medium finish tool steel. Also advisable for THE IRON AGE, March 1943—55 ° A tool steel are the 24-tooth file for semi-fine finish and the 34-tooth file for fine finish. When substantial amount stock must removed, 14-tooth file for roughing and 34-tooth file for finishing would the most profitable choice. Frequently used the “mill cut” (not milled teeth) file. This file has teeth per in. and finishing semi-finishing file for all steels. The degree finish depends the pres- sure applied and the analysis the material being cut. The vixen cut important the bastard because was developed file aluminum, brass, copper, zinc any very ductile metal having the tendency clog ordinary file teeth. The vixen file has large knifelike teeth milled across the face the segment. performs very well cast iron and also non-metals. The correct speed velocity each case has much attaining maximum band filing efficiency. Inci- dentally, velocities for filing are much lower than for sawing. The following are general recommendations but are course subject decrease in- 56—THE IRON AGE, March 1943 crease depending individual con- ditions. Ft. per Min. 100-125 80-100 High chrome-carbon steel ... 45-50 Cast iron Brass and copper 100-125 Phosphor bronze and beryllium Stainless steels .......... 50-75 Nickel silver and Monel metal 75-100 Duraluminum-dural and alum- 100-125 f LEFT tion. not all-purpose file, filing whole, but fast cutting and will better job than coarse cut files usually used connection with the materials mentioned above, comparison with other coarse files, the short angle file gives the following results: Cast iron—Cuts per cent faster and leaves superior finish free from chatter marks. LEFT 6—Faster cutting speed and superior finish are obtained with short angle files developed for work cast iron, non-ferrous metals and most plastics 1G. 5—Automatic feed mech- anism contour sawing ma- chine proves most valuable for band filing. This especially true for finishing medium weight large parts. Bakelite, builder’s board and other non-metals 110-125 Short Angle File Recently there have been numerous from industrial plants for fast-cutting production band file for cast iron, non-ferrous metals includ- ing aluminum, brass and copper, and most plastics. The qualities desired such file were that non-clog- ging, cut faster and leave finish superior that produced with the present coarse cut file and still en- tirely eliminate chatter. After considerable research, the short angle file was developed. shown accompanying illustra- finish free from chatter marks and chips not clog file the case other course cut files. Brass—Cuts per cent faster, very consistent cutting speed and non-clogging. Finish good entirely free from chatter marks. Ampco bronze—Cuts per faster, thus shows great differential cutting time irrespective the toughness this material. The fas cutting speed the short angle file this case due the self-cleaning property the gullet which allows the tooth form full chip. Aluminum—Cuts per cent with identical non-clogging effects with the cutting bronze. faster but leaves finish similar other coarse files since the latter not clog with this material. meg the high ship the ing yard nish ting arse ve, the ster rom speed eloped ferrous arks and the case peed and and narks. per cent ifferential The fast ip. ent fastel effects as pronze. per cent latter ROUSCH Timken-Detroit Axle Co., Detroit placed today upon hardenabil- steel. rapid and convenient means determining the hardening properties and first indication the possibilities steel, but draw all our conclusions the basis hardenability neglecting the very important consideration ductility. generally conceded that steel will perform best can fully hardened its maximum hardness and then tempered back the hard- ness desired. tensile strength closely proportional hardness, can said that hardenability strength, rather the capacity for strength especially the strength different portions across cross-section. The elastic limit and endurance limit are proportional hardness provided initial hardening complete, but are not always after incomplete initial hardening. Elongation, reduction area and impact properties show definite re- lationship hardness and strength the lower hardness ranges, but the as-quenched condition and the high hardness ranges, this relation- does not always hold. There are which are used these con- ditions. this case, laboratory tests actual parts are the only safe and sure means prov- ing the value steel. The harden- test has been wonderful a a =v 7 Steel The author discusses the relative machinability various steels and their action shearing, carburizing and heat treat- ing. The material presented herewith has been abstracted from paper Mr. Rousch presented before the War Engineering Produc- tion meeting the S.A.E. last January. specifications and was probably the only one suitable, but for the above reasons, the real value should confirmed and verified laboratory and performance tests. This being done rapidly pos- sible. There are applications which not require full, deep hardening. face, some parts perform better they not harden throughout. shafts and members subjected torsional stress only, has been found that high surface hardness and lower center hardness gives the best torsional fa- tigue properties, also wear and shock resistance. Then there are number automotive parts being used today, which have never been fully hardened and yet are giving good performance. With the commercial limits neces- sary any alternate steel natural not expect match the hardenability the original SAE steel exactly the core hardness any point gear, for instance, there has definite limits. can determined per- formance testing that given gear will satisfactory with core hard- ness range say points, Rockwell specifications for hardenabil- ity, limits likewise have con- sidered. Hence hardenability band instead single line curve estab- lished. One example this shown Fig. which the hardenability band showing the limits required for 8744 steel for axle drive shafts (30 heats included). The curve out- side the band represents heat which would not give the required production shafts were shipped other plants for hardening. The first specifications for the steels published are shown Table This covers the manganese- molybdenum, 8000 8500 series, and the chromium nickel molybdenum types, 8600 8900, inclusive. The carbon molybdenum were designated the 4000 series. Alternates for practically all the alloy steels pre- viously used were selected from this list. These steels were ordered manu- facturers and tests made produc- tion and the laboratory. Some trouble was experienced with the man- ganese-molybdenum series the low carbon carburizing grades. Core hard- nesses were high and ductility and impact strength were low. Improve- ments heat treatment, however, have made possible make good gears 8024 and 8124 steels. THE IRON AGE, March > with angle f-cleaning ich allows 3 | has been used for studs, bolts and capscrews, both machined and cold headed, and when hardened tween 200 and 400 Brinell excellent properties. Since the great- est shortages have occurred molyb- denum these steels have been practi- cally eliminated, however. far the most popular the steels have been the 8600 series and 8700 series. the carburizing grades either type makes good gears. While there are only five points difference molybdenum the 8700 series are probably better for heavy duty gears. The 8630 grade used for number structural parts. can water quenched and with hard- ness between 200 and 400 Brinell shows good fatigue properties. About the time the 8000 series were being well established and their use for important applications was showing gradual growth, further shortage the strategic alloying elements made necessary further re- ductions order insure uninter- Shortages molybdenum have be- come very serious, making neces- sary conserve this alloy wher- ever possible. Watchful and careful checking the scrap situation showed nickel-molybdenum series which could made with little alloy additions. The alloy contents per cent were: Chromium ....... 0.20 0.40 Molybdenum ..... 0.08 0.15 making experimental heats with these alloy contents, plus slight modi- fications silicon and manganese, hardenabilities were found compare favorably with those all the important alloy steels. This has led the formation supplementary list National Emergency Steel Specifications. The first these the 9400 series with very low alloy content. The next the 9500 which the same the series, 8600 series with additional silicon and hardenability and for heavy sections. the chromium situation looked little better, the 9600 series have been added. These steels have chromium, silicon and manganese the principal alloy- ing elements. Within the last couple months has been necessary alter some these specifications account the alloy content the available scrap. The percentage nickel has been running higher than was antic- ipated and the limits for this element are being broadened allow wider range. Strange may seem, the percentage nickel the 8600 and 8700 series will changed TABLE First Published Table Steels 8024 0.22/0.28 1.00/1.30 0.10/0.20 8233 0.30/0.36 0.10/0.20 8245 0.42/0.49 1.30/1.60 0.10/0.20 8339 0.35/0.42 1.30/1.60 0.20/0.30 *NE 8442 0.38/0.45 1.30/1.60 0.30/0.40 8447 0.43/0.50 1.30/1.60 0.30/0.40 8630 0.27/0.33 0.70/0.95 0.15/0.25 0.40/0.60 0.40/0.60 *NE 8724 0.22/0.28 0.70/0.95 0.20/0.30 0.40/0.60 0.40/0.60 8739 0.35/0.42 0.75/1.00 0.20/0.30 *NE 8749 0.45/0.52 0.20/0.30 0.40/0.60 0.40/0.60 8817 0.15/0.20 0.30/0.40 0.40/0.60 *NE 8949 0.45/0.52 0.30/0.40 0.40/0.60 0.40/0.60 the SAE grades. from 0.40-0.60 0.40-0.70 and the 9400 series from 0.20-0.40 0.20 0.50. The extremely critical condition molybdenum has forced greater re. ductions this element and the 8700 series except for 8720 ing deleted. 8817 and 8949 and also 8547 having high molyb- denum contents have all been deleted, also 8339 and 8442. The lat- est list (as Dec. 17, 1942) shown Table II. Cold Shearing Bursts From actual production experience with the steels there have been few cases reported flakes bursts large forging bars. This happens the larger bar sizes and especially prevalent the steels high hardenability. The condition remedied slow cooling the mill after rolling. The writer encountered this only one heat 8720 This heat had scrapped cracked cold shearing and could not used for forgings. forging there has been very great difference between the old SAE alloy steels and any the steels. Annealing and Normalizing has been necessary for all manufacturers use their available equipment for normalizing and an- nealing, there have been great changes cycles changing the steels. Most all the steels spond the cycles formerly used for the SAE alloy steels. The carburizing grades the steels apparently require less time cooling than some There have been some special short annealing worked