The Iron Age 1943-03-11: Vol 151 Iss 10

11, 1943 = 7 | -row Roll Neck Bearing used Timken and work rolls. Back-up Roll Neck Typical Timken Four-ro -high mill. Bearing mounting for four The One Test For Every Decision— TRADE-MARK REG. U. 6. PAT. TAPERED ROLLER BEARINGS » MAR 1943 Keep for Victory with all Timken Operators rolling mills equipped with Timken Roll Neck Bearings find the these bearings big advantage—espe- cially under war-time conditions. For instance, Timken Roll Neck Bearings not require complicated lubricating systems, there are delicate parts handle when changing rolls; this makes roll ing quicker and easier. Another thing, there adhesion bear- ing surfaces during involuntary shut-downs, mills can re-started without releas- ing roll pressure. This saves steel because the gauge maintained constantly under Furthermore, the tonnage records Timken Roll Neck Bearings are unsurpassed any other roll neck bearings. will pay you keep these points mind when buying new mills modernizing existing ones. The Timken Roller Bearing Company, Canton, Ohio. =| y | SS Net and Big Jobs Still Greater Ones ARS and tubes the mile, commercial shapes multiplied variety speeded into war output today, peacetime products tomorrow. busy mills all over America, draw benches modern type are fabricating ferrous and non-ferrous metals and their alloys—a 24-hour, high-tempo job that cannot wait. With Cleveland Worm Gear Drives need not wait— because you can depend Clevelands deliver continuous flow power—not alone benches but other critical mill equipment well. The Cleveland Worm Gear Company, 3252 East 80th Street, Cleveland, Ohio. Affiliate: The Farval Corporation, Centralized Systems Lubrication WORM THE JRON AGE, published every Thursday the CHILTON CO. (INC.). Entered second class matter November 1932, the Post Office Philadelphia under act March 1879. yearly North America and South America, Foreign $15. Vol. 151, No. 10. MARCH 11, 1943 VOL. NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° Managing Editor, LIPPERT News Markets Editor, ROWAN Technical Editor, OLIVER Associate News Editor, JAMES Associate Editors Art Editor, WINTERS Editorial Assistants BUTTERS Resident District Editors Washington Pittsburgh Washington Chicago Cleveland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham ROY EDMONDS St. Louis SANDERSON Toronto, Ontario BACON Seattle ° ° ° DIX, Manager, Reader Service ° ° ° Advertising Robert Blair, Union Bldg., Cleveland Fitzgerald, 428 Park Bldg., Pittsburgh Herman, Chilton Bldg., Philadelphia Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd New York 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- lished every Thursday. Subscription Price North America, South America and Possessions, $8: Foreign, $15 year. Single Copy, cents, Annual Number, ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and Séth Sts. East 42nd St. Philadelphia, Pa. New York, OFFICERS AND DIRECTORS MUSSELMAN, President HILDRETH, GRIFFITHS, DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, DUFFY CHARLES HEALE Vice-President Vice-President Vice-President This Week in... Editorial Freedom from Want THE IRON Technical Articles Stress Cracking Arc Welding Tool Steel Radiant Heat for Magnesium Melting Production Short Cuts Determining Open-Hearth Residuals Safety Device for Turret Lathes Ford Triplexing Installation Forming Aircraft Extrusions New Equipment: Heat Treating 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 Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices 142 144 146 148 150 151 219 at TED Copyright, 1943, Chilton Company ce Post Office ‘igi’ United States Troops Advancing Oran. Photo Army Signal Helps Make Record Delivery AFRICAN ACKING our fast-moving mechanized Army takes fast-moving production—swift action that starts the minute the order given, that never sleeps, and that turns out jobs days, which normally would take weeks do. Certain equipment already ashore North Africa required important alterations meet unusual battle conditions. The North Africa command said The Ordnance Department said: “RUSH”! The Ryerson customer who got the order said: “RUSH”! —and fifty tons steel were immediately forthcom- ing from nearby Ryerson stock. Result: Delivery the Army one week equipment which normally would have taken many weeks produce. Army-Navy “E” Award the manufacturer and warm letter thanks Ryerson. unusual case? Somewhat— but typical hun- dreds which Ryerson stocks and Ryerson have helped get war equipment started their way sooner our fighting men. all probability, Ryerson Steel-Service can assist you your rush war production contracts, steel required. One the ten strategically-located Ryerson plants nearby. Phone, wire receive quick personal cooperation! JOSEPH RYERSON SON, CLEVELAND BUFFALO BOSTON PHILADELPHIA JERSEY | = nal Corps. | RON AGE ° ° MARCH 11, 1943 ° ESTABLISHED 1855 Freedom From Want the four freedoms enunciated after the historic Churchill-Roosevelt Atlantic Charter meeting, two are basic and long accepted funda- mentals freedom and the other two are euphemistic platitudes. one America, for example, will take exception the goal free speech freedom religious belief. These two basic principles democracy were not originated the historic shipboard meeting the eminent British Premier and the equally eminent American President 1941, but were specifically stated the Bill Rights, years ago. Two new freedoms were added the old established two, order bring them and date. These were the freedom from want and the freedom from fear. Our illustrious ancestors century and half ago did not deal generalities. There was nothing left the imagination, for example, respect the two freedoms which they set forth. People could under- stand what they meant. Our ancestors were realistic. When they spoke freedom speech and freedom religion, one could understand exactly what they meant. And they were position “deliver the goods” these items because such things could attained legislation. The other two freedoms are not easy deliver. Passing laws won't it, nor will waving wands taking rabbits out hats. Take, for example, the platitude “freedom from What does mean? “Want,” the dictionary has two meanings. One without something and the other desire something. makes lot difference which one you are aiming at. Wanting things has made America the most prosperous country the world. Wanting make and sell more and better built our multitude industrial plants and our even greater multitude businesses. Wanting better working conditions and better wages has made American weekly earnings capable purchasing nearly twice much those any other nation. Freedom from poverty probably what was meant freedom from want. But here again have the indefinite rather than the specific which characteristic the demagogic approach the multitude. What may seem like poverty you may riches me. And having less than you want even less than you need has been the greatest spur achievement and personal betterment that has yet been applied the human race. The South Sea islanders are free from want. Nature supplies them with its bounties, the sun warms them, they need little the way clothes. They have more ideal existence, with less effort, than the wildest dreams our Washington idealists could offer, even with the help unlimited national debt. But how much the way invention, improvement, literature art have these wantless people given the | | | | | hun- service er— assist ‘ ” world? y ii J: Millions are Single Accident Not many months have passed since accident meant little more than some personal loss and tem- porary, but easily adjusted, work schedule. Today, that situation completely changed. Every accident the 9,000,000 that occur annually national liability, affecting, not only the output the injured worker’s shop, but also the production other shops. Yes, single accident “injures” millions other workers who are trying desperately reach maximum war American citizens who are striving retain their Ameri- can fighting men who never can have all the equipment and supplies they need for Victory long America careless the home Anything you can prevent accidents will bea real contribution America’s fight for freedom Remove hazards home, drive carefully, erate others traffic, observe safety rules when work, promote safety and safety programs what your position may be. Start today! Think safety, promote safety! Keep workers the job for Victory! Enlist today America’s great against accidents. For complete inform® tion write the National Safety War Production Fund Conserve power, Chrysler Building, New York INLAND STEEL COMPANY Dearborn St., Chicago, Ill. Sales Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas City liable ing. crack condi than susce on re i ad and SACHS Department Metallurgical ing, Case School Applied Science, Cleveland room temperatures withstand static loads close their ultimate strength over extended periods time; however, there exist exceptions this rule, when metals rupture under stresses much lower than their ultimate strengths. The time elapsing between appli- eation the load and failure will external conditions, the presence liquid metal which has solvent action the other metal. The brasses copper-zine alloys more than per cent copper are liable both these types crack- The danger their corrosion cracking increases with the zine con- Under ordinary atmospheric conditions, brass containing less than per cent copper considered susceptible season cracking, i.e., general, structural alloys will Stress Crackin Brass Brasses copper-zinc alloys more than per cent copper are liable rupture under stresses much lower than their ultimate strengths. this, the first two articles, the authors discuss the nature stress cracking, the ammonia and mercury tests, and the effect external loads and cold work. 3 tad front. dom. ther wire, cold drawn per cent, which failed mercurous nitrate under 65,000 lb. per sq. in. tension diameters fracturing the presence com- paratively small external residual (internal) stresses. The homogene- ous, copper-rich, alpha brasses, the homogeneous beta brasses, containing approximately per cent copper, and the heterogeneous, alpha-beta brasses with per cent copper THE IRON AGE, — 7 | 4 ° ° ° i > may develop season cracking favorable conditions. The cracks have intercrystalline nature alpha brass (Figs. and 2); while has been reported that they pass through the beta crystals beta However, appears more accurate state that the path corrosion crack alpha-beta primary beta crystals, from which than from the beta-crystals, (Figs, and 4). The cracking pure brass (52 per cent copper), was found quite definitely the type, (Fig. 5). IG. 2—Longitudinal sections the same wire shown Fig. Same mag- nifications top and bottom. BELOW 3—Corrosion crack Naval brass bolt. 100 diameters. the lightly corroded fractures mal atmosphere, slight amount this finding, ammonia has been sidered the constituent ordinary atmosphere which responsible for the occurrence season Brass, stored clean, dry phere cracks only after long The presence water vapor oxygen has been considered sary initiate How ever, has not been proved, fat that corrosion cracking brass not occur the atmosphere fret from any these constituents. Other corrosive media which might corrosion cracking are: containing sulphur dioxide plus rst ty phurie The statement that 48—THE IRON AGE, March 1943 vest tin ent H. pher wit bras m ount Since ible for racking. and neces How- free Other produce lute ~ ABOVE 4—Corrosion crack cold worked section Naval brass bolt. 100 diameters. RIGHT 5—Mercurous nitrate crack beta brass extruded and per cent drawn. diameters. soap suds might disagrees with commercial observations that neutral soap solu- tions retard rather than accelerate corrosion cracking™. Mercury Cracking The cracking brass subjected stress and contact with liquid metal bears some relation the effects soldering and has been in- vestigated from this angle. Molten tin and lead will cause brass fail sufficiently high stresses are pres- However, more important than the phenomenon cracking contact with liquid solder the cracking brass subjected the attack mer- mercury precipitated from mercury salt solutions contact with brass. While this “mereury cracking” has established relationship the corrosion cracking, its mechanism considered closely related that Values Observed for Cold Stretched 70:30 Brass Wire, 0.109 in. Diameter, Grain Size 0.140 mm. true corrosion cracking. The mer- cury test, therefore, generally ac- cepted suitable measure the susceptibility brass article cracking the atmosphere. However. considerable minority rejects the mercury test, but con- siders ammonia cracking test the suitable criterion. There marked difference between the action ammonia and that mercury, that ammonia penetrates the brass the unstressed condition also, while the action mercury very super- ficial until cracks form along which probably the rather tedious procedure which has prevented the ammonia test from becoming commercial test, while the mercury cracking test recommended standard pro- cedure.* Society for 1940. Testing Mate- Every observer has reported that the results the mercury test scatter erally recognized that mens for this test had care- fully cleaned. The cracking time decreases slightly with concentration mercurous nitrate, while the rate mercury deposition increases. Small variations the concentration the acid have little influence the cracking time; there- fore necessary control the Stretching, Per Cent: 8.5 } composition the solution only with- very close factor which has considerable influence the cracking time the temperature the mercurous nitrate The finding the temperature agrees with general con- ceptions about the effect tempera- ture chemical reactions. Many investigators have preferred per cent mercurous nitrate, per cent nitric acid solution; however, per cent mercurous nitrate, per cent nitric acid solution con- sidered standard this country. While desirable use such standardized methods, has also been observed that the per cent solution not suitable for the visual detection small, slowly forming cracks, which may covered the excessive mercury Samples exposed liquid ordinary according the tests the authors, identical samples subjected the Tensile strength, 1000 area, perce Contraction Per cent elongation, 225 400 625 900 temperature mechanical properties unstressed 70-30 brass 190 deg. mercurous nitrate solution. ever, samples tested nearly per- fect vacuum exposure liquid mercury cracked much faster than when tested normal atmosphere. Therefore, neither the presence air nor moisture are necessary factors the cracking the brass. sur- face layer apparently formed within short time when the tests were conducted with the specimens exposed the air and decelerated the reac- tion between the brass and the mer- Such surface layer either does not possess the protective effect continuously removed the specimen exposed the mercurous nitrate solution. Specimens subjected mercurous nitrate room temperature under THE IRON AGE, March 1943—49 ler ore ‘ | | | stress, causing cracking within "te conditions which would either cause not cause cracking after extended exposure, showed that exchange mutual diffusion mercury and both copper and zinc had taken place. Freezing the mercury cooling the temperature liquid nitrogen eliminated any intercrystalline crack- ing under external loads. The diffusion mercury and sub- which can explained alloying amalgamation, such slight decrease tensile strength and elongation, but increase ductility measured the contraction area, (Fig. 6). These creased with the time room tem- perature. External Loads The effect quantitatively known stress produced applied external loads has only lately received con- sideration. Cartridge brass (70 per cent Cu, per cent Zn) strip the annealed and rolled conditions will crack within days the mercury test subjected tensile stress above 13,500 lb. per sq. in. but below 18,000 per sq. the contrary annealed cartridge brass rods were found fail ammonia test only after days the applied tension was but 5,000 10,000 per sq. the exact time depending upon certain vari- ables; and similar observations were made Muntz metal (60 per cent Cu, per cent Zn), and Naval brass (60 per cent Cu, per cent Zn, 0.75 per cent Sn) rod. Above these limits applied stresses the time crack- ing decreases the stress creased. The data obtained the authors permit more general evaluation the relation between stress and cracking time mercury Cartridge brass wire, and presumably any other high brass (64 per cent Cu) product, will crack con- 50—THE IRON AGE, March 1943 time Sec Crackin External load, 1000 7—Effect external loads cracking tendency mercurous nitrate cold stretched brass wire various tempers. Diameter, 0.109 in.; previous grain size, 0.140 mm. tact with mercury (metallic de- posited from salt solution) only tensile stress above certain limit simultaneously present the sur- face exposed the mercury attack. This holds true for annealed, cold- stretched, cold-drawn, and relief-an- nealed wire. Tensile stress may externally applied may residual retained from cold drawing, combination both. stretching annealed wire, brass troducing residual stress. Conse- quently such wire will crack only subjected external tensile stress above certain limit (Fig. 7). The cracking tendency cartridge brass decreases progressively the amount cold-work strain-hardening in- creases, providing residual stress ab- sent; and the minimum applied stress which will cause cracking mer- curous nitrate solution increases with increasing cold-reduction. The companying table shows values ob. served for cold-stretched 70:30 brags wire, 0.109 in. diameter, grain size 0.140 mm. (Fig. 7). These values higher than previously reported. This can explained the fact that the stress causing cracking tests made other investigators was not ex- ternally applied, but was present residual stress, which generally underestimated the usual stress measurements. tion has resulted from three factors: (a) The disregarding stresses, (b) the partial release stresses the action dissection methods well the method re- moving layers from the outside inside article mechanically dissolving (the energy released such methods probably being dis- seminated heat), and (c) the dis- regarding the stress rebief effects resulting from localized heating using the above methods. The effect cold work proper can explained the generally cepted conception that causes progressive fragmentation frequently considered equivalent the transformation the ture into one having smaller grain size. This decrease effective grain size cold work indeed reduces the cracking tendency similar ner does the reduction the con- ventional grain size the annealed condition. Editors’ Note: Next week, cluding this investigation, the authors discuss residual stress and its pendency upon the type and magni- tude cold work, sum the portant general features stress cracking and investigate theories the phenomenon. pli ste all the th: spe ple yle hoy slo ple ten ben deg the brass 7). rably This the made erally stress ctors: ise ection t-ring re- lly leased dis- ing can work ivalent struc- grain grain ces the con- authors its the im- RUSHMER UNGSTEN, one our most strategic materials, heavy constituent high- speed steel, and behooves con- serve what already have our plants. this can done, will real contribution our full war ef- our present supply, welding of- fered means this accomplish- ment. taking advantage this process, great savings dollars and cents well time can accom- plished making use material which formerly found its way the scrap barrel. Even small pieces can used economically tips tool steel shanks. Many attempts have been made weld tool steel (especially the high alloy steels) with either coated un- coated low carbon steel electrodes, but they have been unsuccessful. has been amply demonstrated, however, that all tool steel, including high speed steel can successfully welded using the 18-8 stainless steel elec- Figs. show sample test bars made are welding carbon tool steel 18-4-1 high speed steel. The sam- ples were preheated with the acet- ylene torch, then are welded with 18-8 stainless steel electrodes. better, however, heat the parts weld- slower and more uniform. The sam- ple was heated the proper forging temperature and forged the center original size in.), shown Fig. Fig. illustrates this same sample deg. Previous this bending test, the test bar was heated the forging Arc Welding Tool Steel With Stainless Conservation high carbon and high speed steel can achieved arc welding composite tools, using stainless steel elec- trodes. the proper procedure used, there grain growth the high speed steel due the high arc temperature. This paper was one the entries the recent $200,000 award program the James Lincoln Arc Welding Foundation which indicated annual cost savings almost billion due arc welding. temperature and bent the weld angle deg. then straightened out flat again, and then reversing the sides was bent shown the photograph. this last bending test there were signs the weld coming apart. Fig. shows weld similar that Fig. The stock used was in. One piece was carbon tool steel, the other piece was 18-4-1 high speed steel, welded with 18-8 stainless steel electrode, 3/32 in. diameter. After the welding operation, the test piece was forged smaller size, in., without any signs failure the weld. the right Fig. shown this same specimen after tortional test. was twisted 180 deg. without any signs ruptur- ing the weld. well not spread the weld over too great area, weld equal strength long one; besides, conserves our limited supply stainless steel. The reason why the welds cover such large area shown the photograph due the stretching the steel during the forging operation. another test bar two pieces 18-4-1 high speed steel were welded with 18-8 stainless. the test there appeared three small rup- tures two sides the stainless steel zone. These small ruptures were about 1/64 in. wide and the same depth. After the polishing and buffing operations they had entirely disap- peared. Very little work has been done date welding two pieces high speed steel together, but from present tests looks quite encourag- ing for the are welding process. few broken high speed steel tools have been welded emergency and are still giving good service. there were IS. views test bar welded with stainless steel. Upper half high speed lower half, carbon tool steel. This piece was forged down after welding. THE IRON AGE, March ° ° ° > U-bend test welded sample shown Fig. The weld may plainly seen the middle. failures composite tools the welds and the writer assumed that the apparent brittleness was due the formation new carbides result the high temperature the weld. The temperature the arc estimated 7000 deg. get the best results from 18-4-1 high speed steel the temperature should not elevated much above 2350 deg. Above this temperature grain growth develops rapidly. study this effect, two pieces SAE 1095 steel were weld- piece 18-4-1 high speed steel. One weld was made with 18-8 stainless steel electrode; the other piece was welded with phosphor bronze electrodes. Three samples were cut from this bar, one from the stainless steel weld, one phosphor bronze weld and the third from the center the bar which was not heated. evident Fig. from comparing the microstructures adjacent the weld with the unaf- fected high speed steel that there little grain growth might suspected. will require further study determine just what caused the failures and provide remedy. machine composite tools after weld- ing, but the tools are heated 1500 deg. quenched oil, then are annealed according the standard practice for high speed steel, dif- ficulty will experienced. Also, has been noted that this treatment applied tools with thin sections gain strength and less breakage result. Many tools can welded without- machining the surfaces. forg- ing rough grinding perfectly satisfactory. course, better bond effected removal the scale. Phosphor bronze electrodes can used good advantage some tools. The cost phosphor bronze less than stainless steel. Tools made from high speed steel must forged and hardened before welding with phos- phor bronze. Carbon tool steel, the other hand, can welded either before after the welding. Application Lathe Centers The demand for better lathe produc- tion requires greater feeds and speeds. thus making the carbon tool steel cen- ters unsatisfactory. High speed steel can used substitute. The old steel centers can salvaged annealing, then machining shown Fig. The composite cen- ter then welded around the groove. Even high speed steel centers that have become too short, can an- nealed, and new center welded on, illustrated sketch. After weld- 3—Before and after twisting test another welded test bar. per half SAE 1095; lower half, high speed steel. ing has been completed tant anneal the piece relieve the welding stresses. Fig. shown countersink us- ing the shank old sketch amply illustrates the procedure follow. The cost high speed steel for this blade was less than The cost material, made entirely from high speed steel would have been $6. addition the forging and machine costs would three times 4—Microphotographs (250 diameters) sections test bars. (A) Junction stainless steel deposited metal (upper) and high speed steel. (B) Junction phosphor bronze weld metal (upper) and high speed steel. (C) High speed steel structure out weld 52—THE IRON AGE, March 1943 heat affected zone. 4 the bon bee! stee and ing witl met sma stee eye. was was toa was the chin give cede tem] ing Hen eye fairl but heat ting desig sence durir the flat preve leave and 3/32 Fig lathe, other serve sign annea have Vice the cost for the high speed steel. Made shown, material and labor would not exceed $3. Fig. shown the method used welding extension tap. The stock used for making these exten- sions can drill rod even low car- bon machine steel. This method has been used countless numbers taps, drills, and reamers. Machine steel for extending the length drill usually satisfactory. Even pipe taps with short shanks are welded and give good performance. weld- ing taps well cover the threads with asbestos thin piece sheet metal. This precaution due the sputtering the which may cause small globules hot metal deposit the threads. Fig. shown high speed steel broach which had broken the eye. About in. back the eye was cut off grinding, the temper was drawn and the stub end ground toa point. piece in. drill rod was ground point and welded the broach shown. When the ma- chine work was finished, the eye was given spring temper. con- ceded that carbon tool steel properly tempered will withstand greater pull- ing stresses than high speed steel. Hence the broach was stronger the eye than when new. Conventional square tool bits are fairly satisfactory for light cutting, but when working against time and heavy cutting they fail due the springing, shattering and the absence body the tool carry away the heat rapidly generated the cut- ting edge. Fig. shows tipped tool designed partly overcome this ab- sence body carry away the heat, during heavy, hogging cutting. the contacting surfaces are perfectly little welding will required. prevent drawing the hardness not leave the arc too long one place and not use electrodes larger than 3/32 in. Fig. shows roughing tool for other designs have been used con- serve high speed steel, but the de- sign shown worked out being the most practical. These high speed steel points can forged swage, annealed, then cut desired length power hack saw. Old tools that have become too short for further ser- can forged meet these re- After the welding has been completed they are heated and 1G. 5—Composite lathe center with high speed steel point welded the carbon tool steel shank. — — — — — — — — —_ — 7—(Left) Taps fractured the shank can reclaimed welding extension. Fig. (Right) Broach reclaimed welding new eye. 6—Countersinking tool made welding high speed tip old drill shank. 9—This design was made largely provide larger heat dis- sipating capacity than available the square tool bit itself. the con- tacting surfaces are perfectly flat, little welding required hold the high speed steel tip the shank. 10—This type tipped rough- ing tool for lathe planer proved very practical. THE IRON AGE, March r ~Weld f Up- igh the us- The speed $1. have and high weld i sidered good practice give all welded and forged tools good an- nealing after these eperations. The cost high speed steel for in. roughing tool $3.45. The labor cost smith and helper 80c., totaling $4.85. The cost medium carbon steel for the welded tool would 12c. the high speed steel tip 16c. The labor cost the welder, 25c., making to- tal 53c. saving $3.72 per tool the above size. Overhead has not been included these figures. the past many these short pieces have found their way the scrap barrel. Not satisfactory 12—Two types inside thread- ing boring tools. tipped forming tool used planer. ° ° ° LEFT Fic. side cutting tool for planer. Fig. shown heavy side these four tools. Four other tool for planer. tools were ordered made in. square, high speed steel, which would cost for the steel alone $61.47. addition this $2.48 must added for the forg- ing operation, totaling $63.95. The cost medium carbon steel for the shanks the welded tools was $1.91. The cost high speed steel for the points was $6.14, and the cost forg- ing these points prepare them for welding was $1.25. Labor cost arc welding the tools was $1.20, making total cost $10.50. Are welding has made possible save $53.49 RIGHT 14—Because lack material, this big gage was made SAE 1045 steel tipped with carbon tool steel. BELOW 15—A set hammer banded with stainless steel prevents chipping the head. The head hardened and drawn after the welding operation. IRON AGE, March 1943 designed like Fig. 11, when made with shanks SAE 1045, effected ing $23.63. Fig. shown two designs inside threading and tool. few instances the upper tool failed the weld, but when made shown the lower view failure ing tool for planer. comple mentary convex tool was also made similar way. They are clamped tool post that used for scores finishing tools with various WwW ill the sig tua bur bust cont tools, with gns tool. tool failure form- made scores radii. The cost high speed steel for these would have been tours and requires four tools for the set. $15.70. The cost SAE 1045 steel was 50c.; cost high speed steel tips, $3.40. Extra labor machining prepare for the high speed steel tips was $3. The cost welding the plates the body the forming tools was $2, totaling $8.40, making total saving $7.30. The main factor that prompted the use the are welding method was the discovery that stock was available for the tools. order the stock from the mill would have delayed the order three four weeks. using the method shown, the tools were made immediately. and the order was shipped record time, which all important factor dur- ing this war emergency. unusual size. The material specified was carbon tool steel, but since this was not available, the gage was finally made from SAE 1045, with tool steel tips are welded illustrated. make easier forge, the gage was made two pieces and arc welded the center. Only the two small points were re- Radiant foster greater uniformity heat delivery over the sides and bottoms magnesium melting pots, the Selas Co., Philadelphia, has adapt- the ceramic-cup radiant gas burner the firing furnaces especially de- signed for magnesium metal produc- tion. The photograph shows the larg- est units recently built. Eighteen radiant-cup gas burners are employed the top row, the bottom the circular pot setting. Gas and air, premixed correct ratio, through individual line and manual valve. Once the balancing valves are set, single-valve two-point control, ac- tuated thermocouple the molt- metal, operates throttle open the manifold mixture supply all burners once and automatically maintain pouring temperature 1350 deg. the pot all times. auxiliary thermocouple the com- bustion chamber connected into the system that maximum pot temperature determined the user can never exceeded. Thus the maximum temperature gradi- quired hardened and ground. There was saving labor and material, but again the main factor was race gainst time. Fig. shown toolsmith set hammer with head banded with stainless steel. When these set ham- mers are left soft the head they are soon mushroomed, and hardened they are liable chip and injure some one, are welding band stainless steel was resorted for longer life and safety. preparing for the weld, the head the set hammer forged down trifle. After the weld- ing completed, the hammer hardened the head end and drawn 750 deg. careful not weld the tip end the hammer for this what should hard. For lighter work, band phosphor bronze may give satisfactory service. Stainless steel being austenitic will not harden. Also non-carburiz- ing. Both these characteristics are used good advantage certain parts machine construction. case hardened work the area that has welded after hardening coat- with stainless steel before ing. Then after carburizing and Heat for Magnesium ent through the pot walls can lim- ited. operation, each refractory burner cup attains uniform high in- hardening welding can safely done the protected, non-carburized area. Occasionally there place where there more less impact piece high speed steel. arc welding thin band phosphor bronze the part will function remarkably well. difficult task give the cost data welding these composite tools due the fact that there are many designs and sizes which affect the cost each tool. But perfectly patent, especially the tool engineer, that when material costing from 5c. per lb. substituted for mate- rial costing from 80c., there must large saving. The cost welding these tools trifle more less than the forged tool. Moreover, welding easier and much more pleasant work than the smithing op- eration. welding these tool steels, clean and careful workmanship required. The welder must careful avoid slag inclusions good results are ex- pected. may impress some that requires exceptional skill produce good weld, but the welding operation shown Figs. was the work man having months’ experience. Melting candescence and completes the air-gas combustion reaction entirely within the cup concavity. THE IRON AGE, March | | | "yf, | | | it | Ail +. 56—THE IRON AGE, March 1943 LEFT Kirksite has been substituted Nelson, for flash electrode dies, with insert lining piece copper substituting for the solid copper formerly used. However, kirksite dies often have indentations created when the molten metal cools. weld and reface level surface necessary. The device shown above, suggested Vinsonhaler, allows any angular face the die raised lowered level position. Raising and lowering done overhead crane which hooks into the rings the top the leveling device. RIGHT quick change boring bar, de- vised Victor saves 61.6 hr. lathe time each C-54 transport. Cutting tools are inserted into the bar, shown right hand; all types and sizes cutters can placed with the two set screws. The machinist then needs make but one setup for the various diameters cuts which are made unit, such the aluminum hydraulic booster valve shown beneath Sundquist's right hand. Boring, threading and finishing are all done with one setup. The same principle can used ex- ternal cuts and precision lathe work. LEFT Six hours plane are saved with Davis's inner wing electric wire loom jigs. The wire layouts installed later the plane are laid out and tested one operation, then removed from the loom jig and in- stalled. RIGHT outlet the side instead the top electric junction box keeps dirt out the twistlock re- This idea Burt Smith's has obviated short outs, and has re- duced repairs from 50.boxes week five. suggested employees, save Douglas Aircraft Co. hours man and machine time each plane. RIGHT portable pneumatic notching tool attachment enables one man work which formerly took two, and save 21.4 hr. each C-54 transport. Previously, airplane skins were placed the jig, marked for notching, and then removed for the actual notching. This attachment, suggested Kennedy, makes possible notch the skin the jig. LEFT With this combination broach, burnisher and dimpling tool, devised Wood, scoring and tearing metal prevented. The previous method made rough edged hole which tended crack the stock when the dimpling operation was performed separately. Now the hold broached, burnished and dimpled one punch operation. RIGHT This striping machine, invented Walter McGarvin, saves hr., 160 ft. tape and $8.26 the 140 ft. striping for each plane. The striper barrel holds half pint lacquer, poured through cap. the lower end, hole per- mits lacquer flow into groove around the periphery brass roller in. diameter, which turns pin supported frame fitted over end barrel. cross member the frame serves spreader, conduct- ing lacquer from the groove toward both sides. adjustable guide arm enables the operator follow marks. LEFT With this new flange jig, suggested Jack Doyle and Griffis, 180 parts can completed hydraulic press. Master block and two inserts make both right and left. THE IRON AGE, March @ % j j Determining Open Hearth ESPITE the fact that much the early success the spec- trograph occurred the fer- rous industry, subsequent plant appli- relatively slow. However, contrast this, whole sections the non- field employ the spectrograph considerable extent this favorable attitude toward analytical methods thé non-ferrous work results from the relative shortness time involved melting and refining practices and the difficulties encountered chemical analysis. is, however, quite prob- able that the inherent accuracy and speed operation the spectro- graph, combined with its recently de- veloped dependability and low oper- ational cost, will also serve bring about its greater adaptation the ferrous metal field. Spectrographic history the steel industry has been one tentative trials. Several foundries have made very expensive and excellent installa- tions, but other foundries have been slow follow their experience. Several steel mills and secondary pro- ducers have made installations for quality control semi-finished shapes and sheets. Raw product control, vast field, has only slightly been touched, although with unusual suc- cess. Claim work, also qualitative nature, has employed the services the spectrographer from time time. For example, the failure some deep drawing sheets was traced brittle- ness resulting from very low con- tamination zinc. There one field, however, that offers unusual promise for spectro- graphic control. the open hearth, preliminary analysis for residuals made the bath immediately after the melt down. The residuals may in- clude copper, nickel, tin, chromium, silicon, molybdenum, aluminum, and manganese. The need for rapid but accurate analysis becoming more and more apparent not only for the familiar reasons, calculation for alloy additions, diversion heats, but also because the grave scrap sup- ply situation existing present. 58—THE IRON AGE, March 1943 telle Institute and others have emphasized the increasing resid- ual content open hearth steels dur- ing the past decade; but the war, provoking scrap shortages, erratic scrap sorting, and tin scrap charging, has placed question mark beside the residual content every heat steel. For the chemist, the determination residuals, best difficult and some- times tedious, now ingly more difficult. Normal facilities are inadequate, competent personnel not readily accessible, I—A portion the spectrographic unit can seen the extreme right. the background are the d.c. arc, a.c. arc, and a.c. spark power units. The generator set, which supplies constant voltage, located beneath the table the treme left, with controls brought out panel above table level. time for sampling and analy- often not available. For these the chemist has had resort addi- tional methods other than the normal “wet techniques.” here that the spectrographer and the steelmaker are commencing work side side. ses Spectrographic Laboratory should recognized that the spectrograph has applications other than those associated with war pro- duction and the conservation stra- tegic alloys. The post-war period will probably one highly competi- ances and finer distinctions than now prevail. The spectrographic method these requirements. addition those already men- tioned, numerous other elements such titanium, arsenic, antimony, zine, cadmium, bismuth, boron, beryllium, zirconium, cobalt, columbium, and tungsten can adapted quantita- tive spectrographic techniques. There is, fact, another large field for spee- tion analysis, particularly for the these elements, since the wet methods are usually long and difficult. snul mov brat com: ings foun mill resul ticul: pass tive market with even closer for example, requires day and for analysis. Spectrographically, possible determine cobalt less than one hour. The elements steel which cannot spectrograph are carbon, sulphur, oxygen, hydrogen, nitroge® permanent gases, and halogens. itatively, about elements all checked the spectrograph. The desirable location for the 7 ~ all ear Residuals possible the furnace which the ing immediately adjacent the floor open hearth often preferable having the laboratory the open hearth floor itself. For electric fur- naces, the spectrograph may placed the floor. general, three condi- tions will determine the laboratory site: Vibration: The usual types vibra- tion may overcome mounting the spectrograph and densitometer steel plates and suspending them from the ceilings with springs. Rubber snubbers are used minimize movement. The pulsating type vi- bration almost impossible over- come. For severe cases, adjacent build- ings having little vibration will found the best solution. Dirt, Fumes, Smoke, and Heat: For mill locations, complete air condition- ing mandatory insure accurate results and low maintenance costs. Electricity: Stray electricity, par- ticularly high frequency nature, Routine Spectrographic Analysis The steel plant spectrographic laboratory and how utilize spectrographic analytical methods for quantitative well quali- tative determinations residual contents open hearth charges are described this article. ROZSA Spectro Republic Steel Corp., Cleveland can minimized grounding all apparatus and cabinets, using metal darkroom partitions, and employing transformer chokes. Apparatus selection almost en- tirely dependent upon the application although initial applications nearly always can depended upon in- crease scope with continued use. the case the spectrograph itself, for various reasons the use concave 2—A master spectrum incorporated this projection-comparator type densitometer. The operator shown pressing the button which flashes the spectrum lines the screen immediately before her eyes. measuring the density light passing through these spectrum lines the content element the sample steel under test determined. gratings has been the subject much misinformation. not uncommon pick article the spectro- graph, written five six years ago, and read the flat declaration that con- cave grating spectrographs can never adapted quantitative work. How- ever, should also remembered that years ago some the leading spectroscopic authorities agreement that quantitative analysis the spectrograph was not possible all. often the case with anything new, the label “radical” “un- tried” often attached. Even cursory survey spectrographic liter- ature the past two years will show the error such statement. While often deemed stances gratings being use since 1880 are known. Precision ruling has been enhanced reduce ghost lines negligible proportions, and evap- oration aluminum films upon the surface the grating has made them faster and still less fragile. The inability the grating spectro- graph produce stigmatic images has long been emphasized severe fault, but today being answered such mountings the Wadsworth and the use the secondary focus, Sirk’s method. Analysis Efficiency From the basis spectrographic efficiency, dispersion power are important. Dispersion may defined the ratio the change the deviation the light beam the change the wave length. Reso- lution the ratio between the aver- THE IRON AGE, March | | : a] now men- such zine, and There spec- for ‘thods ° ° ° 5 | | | 4 TABLE Dispersion and Resolution Characteristics Meter Gratings and the Quartz Littrow DISPERSION Wave Length, RESOLUTION Meter Grating Quartz Littrow 1.5 Grating Littrow 2.5 0.12 0.07 2850 0.12 0.12 3500 0.13 0.25 4700 16.5 0.15 0.75 age wave length pair lines that can just separated and the difference wave length between these two lines. Especially for steel analysis, high resolution the pri- mary criterion since needed permit separation lines sufficiently for identification and estimate the amounts elements present. disperson and resolution, the usual Littrow, indicated Table has little, any, advantage. fact, the constancy dispersion without magnification crowding near the visible range occurs for the quartz Littrow distinct ad- vantage for the grating type. The table for resolution, however, the deciding factor. Since for steel pre- liminary analysis work, the lines copper, nickel, tin, chromium, molybdenum, silicon, and manganese lie within the 2800 3400 range, the superiority the grating type indicated. When the quartz Littrow type spec- trograph was first adapted produc- tion control, $12,000 for equipment, $25,000 $40,000 for development particular application, and devel- opment period six months two years were not deemed unusual. These costs and this length time were necessary because the spectrographic unit had custom-tailored. Today, the situation has changed appreciably. Completed “packaged” units employ- ing grating dispersion are now avail- able. These units with attendant mated equipment are designed with the ruggedness, flexibility, and con- venience maintenance needed for routine production without sacrifice accuracy. possible without too many difficulties obtain the desired characteristics combining units from various companies. For gratings mounted the Rowland method, long range, 2000 10,000 can obtained for qualita- tive work without disturbing the rou- tine range settings, optics, focus required the quartz glass Littrow type. 60—THE IRON AGE, March 1943 Reasons such these are making the grating unit the most widely used spectrographic instrument this country. enough have had the opportunity use both the quartz and grating spectrograph for steel analysis have registered distinct preference for the grating type. general, two excitation sources are needed. condensed spark con- sisting condensers, variable inductance, and safety controls will usually suffice for work where the metal constituent above 0.10 per cent. Several these units are now commercially available, being rugged, controllable, and adapt- able the severity industrial han- dling. The second excitation source, a.c. arc, will suffice for general qual- itative work and for quantitative work where the metal constituents are below 0.10 per cent. For routine work, preferable obtain one the loading jig varieties arc-spark stand preference the usual Gramont type. Constant voltage needed for the excitation sources and the densitome- ter. Even the mill adjacent power plant, motor-generator source will nearly always needed. planned layout actual use, incor- porating these features, shown Fig. Reproducible film processing for TABLE Accuracy Routine Analysis Open Hearth Melts Spectro- graphic Determination Element Per Cent Per Cent under within 0.05 0.005 0.20 0.005 Copper........ 0.30 0.008 0.05 0.005 Chromium..... 0.07 0.008 many years has been discouraging factor quantitative work. Now, ever, suitable automatic developing equipment, washers, and dryers are commercially available, these, combined with fairly recently devel- oped film emulsions, have simplified this phase work. Densitometers also have improved appreciably within the last few years. advisable, however, specify the projection-comparator type which incorporates master spectrum. Rug- gedness, speed, and repairability are also needed for production work. Such Fig. Considerable room for improvement still present commercially able calculating boards. Greater con- venience and speed obtained the from the horizontal. Drawing for rapid direct calculation also presents difficulties. Preparation Samples simple holder used for initial roughing down, and the specimen held the fingers for the final polishing, 5/32-in. diameter pin can prepared about sec. Grinding jigs, general, are time consuming and not completely satisfactory. Addi- should include strong vise, hacksaw, hammer, substantial table, grinding wheel, and the common repair tools. Sooner later the spectrographer usually finds himself serving repair and maintenance man for all his equipment! previously stated, conditions have changed considerably since the early installations and now pos sible equip and develop routine laborator