The Iron Age 1943-04-01: Vol 151 Iss 13

view modern thrust showing the application Bearings. your piercing mills Timken Bearing Thrust TRADE-MARK REG. U. &. PAT. OFF. TAPERED ROLLER loads; positive thrust ust lock assembly- oom from there equipped with Timken Tapered Roller Bearings operation without maintenance attention. This due radial, thrust and com ’ | placing thrust plocks reduced the vanishing point. Here’s How You Can Learn the Full Possibilities Your Bar Turner the most important tools employed metal turning the Warner Swasey Single Cutter Bar Turner. used more than any tool turret lathes set for bar work. Field studies dozens plants indicated the urgent need for better understanding the several fundamentals governing the setup and operation this tool. The information and many helpful hints assem- bled the new Warner Swasey booklet, “Better Performance from Single Cutter Bar can improve performance this basic turret lathe tool and increase production your shop. Just issued new 32- page illustrated booklet shows how make the most efficient use the Single Cutter Turner bar work. QUICKLY USING THE CONVENIENT COUPON Warner Swasey Service Bureau, Cleveland, Ohio Please send booklet, Performance from Single Cutter Bar Name Company City State 1A-10 Robe Peirc a Men Men Inde lishe Poss Che JO! Turret Lathes Cleveland APRIL 1943 VOL. 151, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager naging Editor, LIPPERT Technical Editor, OLIVER Associate News Editor, JAMES Art Editor, WINTERS Associate Editors Editorial Assistants BUTTERS Regional News and Editors Washington Pittsburgh Washington Chicago Cleveland Detroit OSGOOD MURDOCK San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Ontario St. Louis BACON Seattle ° ° ° DIX, Manager, Reader Service Regional Business Managers Robert Blair, Union Bldg., Cleveland Fitzgerald, 428 Park Pittsburgh Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond 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 Warren, Box 81, Hartford, Conn. Johnson, Market Research Mar. Hayes, Production Manager. Baur, Typography and Layout. ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents, Annual Number, Cable Address Y." ° ° Owned and Published CHILTON COMPANY Executive Editorial and Offices Advertising Offices Chestnut and Sts. 100 East 42nd St. Philadelphia, Pa. New York, U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. GEORGE GRIFFITHS, EVERIT VAN DEVENTER, BAUR, Vice-President Vice-President Vice-President Vice-President Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, Editorial Accumulating the “Know Technical Articles MM. Shell Conserving Alloy Welding Simple Plan for Electrode Stub Control Nickel Plating Fine Centrifugally Cast Flange Welding Light Metal Cutting Off Work In. Diameter Tool Engineers’ Convention Report. Features Assembly Line Fatigue Cracks Dear Editor News and Markets This Industrial Week News Industry Personals and Obituaries Machine Tool Activity Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Prices. Comparison Prices Finished Steel Prices Index Advertisers Copyright, 1943, by Chilton Company (ine.) 142 144 146 148 150 151 152 227 q | é f | 4 | ‘ | | ° ° ° ° ° ° . i | 3 Mahon skill the fabricating welded bases and frames has long been established throughout the ma- chine tool industry. Recognition that skill now ex- tends into many other fields manufacture. The diesel engine base, pictured above, but one several such fittings production for this important industry. Today the extensive facilities Mahon also are being drafted for the fabrication gun mounts, ship assemblies, frames and integral parts electric motors and generators, supports and fittings for elec- tric and hydraulic pumps, furnace great variety other weldments for many addi- tional industries. War production has brought home hundreds manufacturers the superiority welded steel plate the ideal construction for bases, frames, casings and similar fittings. stronger, lighter, waterproof, re- quires less machining and finishing, makes much better appearance—and, most cases, can pro- duced faster and cheaper. Send your blueprints. Our engineers will advise you fairly and frankly whether welded steel plate construction practical for YOUR product. Fabricators Machine Bases and Frames and Many Other Welded Steel Plate Products MPANY H E R : q G ° APRIL 1943 ESTABLISHED 1855 Accumulating the "Know AST week the American Society Tool Engineers held its annual convention Milwaukee. How essential these men are considered the war effort evidenced their being permitted have the usual exhibit spite the pressing demands our transportation facilities. These tool engineers have been largely responsible for the develop- ment our mass production industries. Now they are doing equally amazing job with our munitions products. Show them product part that you want made and tell them how many, and they will write the tooling prescription. Since our war effort began, have learned great many things about production that will bear fruit after the war, when can apply them making products for use instead products for destruction. This knowledge should result some remarkable cost reductions the post- war period. Knowing how make things and having the materials from which make them are the two essentials productivity, and productivity meas- ures national income terms goods and determines the standard living. Combine this how” our tool engineers with the 1500 more new materials made available for use since the start the defense-war program and you have picture post-war possibilities that should show new high prosperity. This year, even with close million our best potential pro- ducers removed from business, industry and agriculture war, will generate national income per cent greater than the boom year 1929. can this with depleted labor force, think what should able when the boys come back from Berlin and Tokio, and put their shoulders the wheels again! : | F e Many new users Inland steel, like our long- time customers, importance and value Inland Uniform Quality. They know that steel unvarying quality major factor conserving tools—in lowering costs—in reduc- ing rejects the minimum—and, meet- ing, even exceeding, war-time production schedules. Take, for instance, certain household appli- ance manufacturer, who not only never had made ammunition, any other war product, but who never before had machined rolled steel. Soon after Pearl Harbor, this manufactur- SS 3 Ss Sy \ Shell being ejected from press after cold nosing from Inland—Preferred accepted large contract for forging and machining shell. Inland immediately started shipping great quantities shell steel Inland Uniform Quality. Steel that has proved satisfactory—so trouble-free —that this manufacturer’s preference for steel from Inland. Supplying steel for shell only one Inland’s war jobs. Every ton steel made the great Indiana Harbor Works goes into war products —from ships parts weighing only few products that are helping close ring steel around the Axis. mi col pe we " pr m) Ta St. Paul, St. Louis, Kansas Cit mm. brass shell case. MM. Shell Cases ° ° ° PHAIR Western Editor, THE IRON AGE Midwest firm, which turned out coin operated machines before the war, described this article. Carbide die life, ingenious, fool- chain type indexing mechanism and several unusual machines developed the company are described. ROM coin vending machines mm. shell cases the conver- sion record the Stoner Mfg. Co. which said one the smallest Midwest prime contractors with million dollar ordnance contract. This conversion, underway before WPB shut off supplies for the company’s peacetime uses, was more than starting entirely new business. While the company did have few stamping presses before converted, the bulk the plant was devoted wood working equipment. order accommodate equipment needed produce the mm. case and the mm. shot, which the company also produces, was necessary prac- tically rebuild the plant. Early efforts purchase the necessary machinery ran into the usual priority log jam and expedite the transition the com- pany purchased many second hand machines, rebuilding them purposes. The most interesting aspect this mm. job the selection ma- chines for the various operations, bearing mind that very few new machines were available when the job was undertaken and the company was forced base its selection largely such used equipment was available. Too, was one the earliest mm. contractors and was forced, with the invaluable aid the Ordnance De- partment, much pioneering. The steps taken produce mm. case, which modern warfare used large volume aircraft and also for anti-aircraft work, are detailed here- with. These details are concerned with the production the brass case, which still being produced large quantities the company, although plans are underway change over steel cases the near future. One the features this com- pany’s manufacturing practice that immediately strikes the eye the widespread use cemented carbide material for stamping dies well cutting tools. All stamping dies and practically all cutting tools used producing the cases are equipped with cemented carbide nibs tips. Aside from the creased die life that results from this practice, the company reports that cemented carbide equipment ab- solute necessity order hold the tolerances set for this ordnance job. This ability reflected very low rate re- jects. also noteworthy that the company has not been required ask for any relaxation the close toler- ances set for this work the Ordnance Department. While comparative data cov- ering regular die steels and dies fitted with cemented carbide nibs are not available, figures are obtainable actual runs the latter type dies. The cupping die shown Fig. ran 5,000,000 pieces before the die had replaced. Tapering dies have run 10,000,000 pieces before re- placement was necessary. Drawing dies are giving million pieces be- fore wearing the point where re- placement required, except the fifth draw where the longer draw keeps die life about 2,000,000 pieces. indication the ingenuity which went into the company’s attack the conversion problem found the fact that, experiencing difficulty obtaining trimming machines, the company purchased several aged machines and rebuilt them into THE IRON AGE, April 1 | ° ° ° > a trimming machines. The same diffi- culty was faced obtaining machines for cutting the cannelure and was met taking parts several ma- chines and putting together “Rube Goldberg” unit which still operating satisfactorily. (See Fig. company also built two 300-ton coin- ing presses, being unable that time purchase new presses ciently long stroke. These presses were equipped with dial feed and are quite effectively performing opera- tion that combination coining and heading operation. They have in. stroke and double dies. producing the mm. brass car- tridge case, the company purchases the disks from outside sources. The sequence the various processing steps given the accompanying table. The first production step wash the blanks strong, hot solu- tion Oakite No. 37, followed hot rinse. The blanks are then an- nealed Lindberg gas fired batch type furnace 1100 deg. for hr. The disks pass water quench which brings them down between 200 and 300 deg. F., which tem- perature they enter per cent sul- phuric acid pickle bath. This fol- lowed plain water and 42—THE IRON AGE, April 1943 soap bath. The latter, which made with pure Armour soap chip, intended neutralize whatever pick- ling acid may left the blanks after this treatment. The soap then washed off plain cold water rinse. This last washing operation set permit very small amount the soap solution remain the brass serve protective coating further action any residue acid. This pickling and washing car- ried special type Ransohoff barrel type unit. The disks are fed into one end and progress through the various washings means re- volving screw and are finally deposit- buggie the discharge end for transfer the next forming op- eration. The first forming operation the cupping, done 150-ton Niagara double crank press with 6-in. stroke. The clutch release was taken off this unit and automatic hopper, see Fig. installed permit continuous feeding. Being unable obtain delivery the press desired for the job, this Niagara unit was pressed into service. While this Niagara doing ex- cellent job the cupping, company 4 engineers believe that single crank press smaller capacity would the work equally well. The cupping operation followed wash, anneal and pickle similar that described previously. The first draw taken 150-ton open back, single crank press, with stroke, running strokes min. with double dies and one operator. Between each draw and during the cupping, the case lubricated with compound consisting Whitfield- Richards Lube-Well No. 19, thinned with cold water. was found, after much experimentation, that this com- pound worked especially well under the conditions this particular job. This solution prepared mixing parts water with part com- pound for the drawing operations and for cupping. The solution pumped over the dies and sprayed the punch, returns from the die. double dies, such the cupping dies, the lubricant pumped through drill holes the lower die assure adequate lubrication this point. The second draw accomplished old Ferracute single crank press, purchased second hand, which was completely rebuilt for its present job. This press has capacity about ABOVE dies with cemented carbide insert (arrow). This die ran 5,000,000 pieces without replacement. LEFT 2—Homemade which cuts the cannelure. The machine has Each spindle station re- volves 900 r.p.m. against cutting tool, and the same time the entire unit moves around the right, timed that each case completes the circle, the cannelure cut. The cutting compound canal the center serves distribute, gravity, the compound equally stations 105 fittec draw back 13-in Fig. head This die pli with pres: forn setu ‘ 105 tons with 12-in. stroke and fitted with double dies. The third draw performed Niagara open back inclinable, 150-ton, single crank, 13-in. stroke press with double dies, Fig. Following the third draw, the case restruck flatten the dimple the head formed during preceding draws. This restriking, Fig. done Marshalltown open side, 75-ton, single die press strokes per min. planned eventually equip this job with multiple feed unit that one press will able the work per- formed three under setup. The fourth draw done old Bliss straight sided, 90-ton double die machine. From this operation, the cases are fed hand into tube which leads into Oakes trimmer which removes about 0.5 in. stock. Then follows another restriking op- eration 150-ton Niagara, straight- side, dial feed press, which preforms the button, reshaping for the fol- lowing operation. The next step indenting the head for the primer pocket and the anvil. town 75-ton, single die, dial feed ma- chine used for this purpose. The fifth and last draw done Nia- gara open back 150-ton, 13-in. stroke chain feed machine. This followed trimming, which another 0.5 in. metal removed special Oakes trimmer which has about in. longer than standard. Heading and stamping the iden- tification marks the head were originally performed simultaneously Toledo 250-ton coining press. The lettering dies are carried the head- ing dies. Heading now done knuckle joint press, ABOVE 4—Third draw Niagara equipped with chain feed mechan- ism (shown Fig. developed the company's engineers. Loading done with both hands from either side. Drawn cases are dropped into skeleton tube, visible lower right side photo, which feeds into buggy. LEFT using cemented carbide die shown Fig. Tube foreground feeds the disks the die. Rod mechanism the right advances the disks the die. the photo not operating position. Fig. developed the company. This press requires only one man operate, compared with four the machine originally used for this pur- pose. This machine automatic throughout and stopped the fix- ture not completely indexed. equipped with air cushion which also acts stripper. The shell ejected through the fixture the rod the index plate visible the left the photograph. Tapering done special hori- zontal machine developed Stoner THE IRON AGE, April 1943—43 in ie ABOVE Cases drop sheet iron chute behind ram and slide into two- wheeled buggies for transfer next operation. engineers and Iron Works. This light press about 18-tons capacity, magazine fed, with 10-in. stroke. The cannelure cut unit, Fig. designed and built company en- ginners from parts old machines. has spindles, revolving 900 r.p.m., which carry the shell cases. Each spindle has adjacent cutting tool and its individual coolant supply. The cutting tool, which cemented carbide tipped, fed into the case means stationary master cam, mounted below the coolant trough. The entire table which the spindles are mounted also revolves and timed complete one revolution each cannelure cut completed that loading and unloading done adjacent spindles. Overflow cases from this unit handled small turret lathes. The mouth anneal which follows 44—THE IRON AGE, April 1943 the cutting the cannelure, done Bliss unit, with each case being held 1000 deg. for seconds, This Bliss unit uses screw for ad- vancing the cases past the gas jets. meet certain specific problems, Stoner engineers have built several annealers their own design which used roller conveyor for advancing the cases. Final stress relieving done Lindberg recirculating type gas fur- nace 500 deg. for hr. After annealing, the cases are cooled and are inspected moving belt and then packed. The final wash, preceding the final BELOW joint coining press de- veloped the company for heading and marking the cases. ” * done eing jets. ems, fur- and and final de- Operations the Manufacture mm. Shell Brass Cartridge Cases *Wash blanks Anneal, pickle blanks Cup Wash, anneal, pickle First draw Wash, anneal, pickle Second draw Wash, anneal, pickle Third draw Restrike Wash, anneal, pickle Fourth draw Trim Wash, anneal, pickle Restrike Indent Fifth draw Trim Wash Head, mark Pierce flash holes Taper Cannelure Wash Final trim Mouth anneal Stress relief anneal Inspect Pack *Washing procedure identical for cupping and first four draws. anneal, done special washing unit designed avoid denting marring the lip the case might easily develop washers where the cases are permitted hit wall against one another. dent nick the Jip can cause serious die trouble undetected. This washing unit equipped with endless belt which are mounted rows prongs right angles, the belt. The cases are slipped over these prongs, one case prong, and carried through spray wash. From the wash the cases are carried into spray rinse chamber and from thence drying chamber where steam coils are used provide the necessary heat. Conserving Alloy Welding XTENSIVE savings critical steel used the manufacture welding rods has been effected the Fisher Body Division Gen- eral Motors. The idea was conceived Fisher Tank plant and has sub- sequently been made other plants and companies whose work entails are welding. The usual practice use are welding rods grip the tip the electrode the holder, the tip being left bare flux allow for electrical contact. Obviously all the welding rod cannot 7—Details roller chain index- ing device for feed- ing cases double die press. number presses, including the machine used for the third draw, shown Fig. are equipped with special chain feed indexing device de- veloped Stoner engineers. This device has proved highly successful and installations are being made number other press plants. This indexing arrangement shown de- tail Fig. The operator, using both hands, loads the cases into the carying rings the rings are carried past the loading end roller chain. The chains are advanced means link arrangement attached the press. This linkage connected triangular dogs, visible the center the sketch, which bear the up- since the last inch the holder and stub must allowed protrude. Thus ordinary welding, from in. the rod discarded. While the length the different types rods used may vary considerably length, nevertheless loss may overcome this loss, Fisher weld- ing engineers developed method whereby 3-in. piece mild steel welded the holding end the rod. The electrode holder grips this piece mild steel instead the alloy rod itself, and thus welder able right case. Should the operator fail load ring, the dog deprived bearing surface and, consequently, the chain cannot advanced. The press, such cases, must stopped, and case inserted the missed ring. rachet device prevents revers- ing the chain, but designed give some back play permit center- ing the case exactly under the ram means fixed guide. Lubricant piped the cases. Aside from complete safety operation afforded this arrangement, the necessity stopping the press correct the missing loading ring provides added incentive the operator keep the press evenly fed. Rod use the rod practically the very end. Besides saving appreciable per- centage strategic electrode mate- rial they effect saving per cent their electrode holder cost. When using conventional out tip welded on, the operator burns the rod down close the holder bringing the holder very close the are and molten metal. Because burns and spatter the life the holder very short. With the tip welded on, the holder never closer than in. away from the molten pool are. THE IRON AGE, April 1943—45 fl <4 4 = Simple Plan for accelerating the production ships, tanks, planes and mul- titude other wartime necessities paramount the minds every American. electric welding the electrode the only concrete vital material that expendable and there- fore subject waste. Unless already straining electrode productive capacity can relieved, this country will delayed attaining ultimate victory. Capacity increase the field electrode makers; reduction de- mand without reduction accomp- lishment the field all users electrodes. The design accepted the Mari- time Commission for its emergency fleet calls for welded construction. With eight ten yards building EC2 type ships, the demand for welding electrodes enormous. The first ves- sel completed the North Carolina Shipbuilding yard required 146,000 lb. manual electrodes varying 46—THE IRON AGE, April 1943 sizes and grades for all tack and duction welding, involving approxi- mately 200,000 linear ft. welds. view the electrode shortage, was absolutely essential that the ag- total 146,000 lb. elec- reduced. This been accomplished. Now vessels are com- pleted this yard requiring only 120,000 per ship. This saving 26,000 lb. 17.8 per cent was effected without making any changes de- sign. was effected through the adoption system that controls the stub waste involved each elec- trode and the expansion the automatic machine welding process. Use submerged melt automatic welding accounts for 2.7 per cent the saving. The remainder 15.1 per cent 22,000 per ship due the control rod wastage. Outline System The above saving was effected adopting the following procedure: (1) The entire shipyard including platen space, skids hulls were cleaned all unused trodes and stubs. (2) Welding electrodes are issued all users prescribed amounts indicated further this report. (See Fig. and Table (3) Each user instructed melt his electrodes within range length from in., save all his stubs, and return them the metal dispense rooms. (4) The length the stubs mea- sured calibrated spring scale later described (See Figs. and 3). (5) Accepted stubs are sealed scrap paint cans and removed the yard. (6) Users with stubs outside the prescribed limits are tional until they have melted their first ones meet the specified range. electrodes Those whose stubs have been refused two occasions are reported their superiors for penaliz- ing. Before inaugurating this system reduc- ing electrode consump- tion elimination stub waste, the entire working area was cleaned all electrode stubs. stubs are is- sued from dles, depending upon di- ameter. This simplifies ac- counting for and number stubs re- turned. wel the bea 1 are ret ope que sys on an we se ° ° Electro cation beyond the reach every welder and tack welder. Each user therefore- had melt his allotted electrodes the published range bear the consequences. are also taken prevent the stubs returned from getting back into cir- culation. The exact this operation will dealt with subse- quently. Issuance Electrodes pointed out the outline the system, electrodes are distributed users predetermined amounts, Fig. welder cannot receive more than one bundle each size time. definite amount was set for each size and for production welder tack welder, the latter obviously quiring much the former. These quantities, tabulated Table were set make each man realize the the commodity but yet not low require sev- eral trips the metal per day. standardizing the weight electrodes issued each man, the necessity keeping voluminous rec- ords indicating how much each man receives entirely eliminated. The time spent distributing metal therefore more than the usual method handing out. Our metal rooms are located under the shipways quickly reached men working either platens ways. This important when limited supply electrodes issued order prevent the loss time obtaining additional ones. With standard bundles each welder will return the same number stubs one size, arrangement that speeds their acceptance rejec- tion. not necessary check any records determine how many stubs what weight should returned. (Table and posted each metal room under the weighing scale where all can see, Fig. Permissible Electrode Stubs planning this program, uniform maximum stub length in., con- sidered normal throughout the entire welding industry, was set the goal attain. Practically speaking, Stub Control Electrode consumption for each Liberty vessel has been reduced from 146,000 120,000 simple system stub control that requires extra supervision paper work. one the reasons why this yard the lowest cost producer Maritime Commission ships the country. This one the James Arc Welding Foundation award papers which received honorable mention. WILLIAM BEGOR Welding Engineer and DAVID McLELLAN Welding North Carolina Shipbuilding Co. Wilmington, the program reduced the stub length in., would have been con- sidered successful. Actually duced the length point below the allowable in. The way this system operates minimum length quired and set in. These limits permitted minimum stub losses (by length) 7.1 per cent in. electrodes and 5.5 per mum 14.3 per cent and per cent respectively. the outset every welder was in- formed that stubs not within the above range would rejected. Simul- taneously with notifying the welders this requirement, signs were placed convenient locations stressing the urgency conserving this commodity. size was designated the spring The expected grumbling and complain- scales color. The sensitivity ing began but ceased soon the system had functioned for two three weeks. Length Returned Stub Congestion the metal dispense room cannot tolerated. Idle con- versation arises readily enough with- out providing opportunity for while welders tack welders are waiting for electrodes. expedite the examination stub lengths, vital the success the system, the num- ber stubs produced each stand- ard electrode bundle was determined and the maximum and minimum al- lowable stub weights measured. The range permissible weights for each TABLE Amounts Which Welding Electrodes Are Issued Tack Welders 21% TABLE Number Stubs Returned Each Welder THE IRON AGE, April Cs lete ued nelt nite the as the the ave the ubs ons eir liz- ing uc- ire vas ode ubs lo- is- etal di- ac- ued re- TABLE Weight Stubs Returned Each Welder x 14 316 x 18 x 18 Min. Max. Min. Max. Min. Max. Min. Max. Max. (red) (red) (blue) (orange) (red) (green) (green) Note: All weights oz. Colors refer range markings dial spring scale, Fig. the scales was increased lever ar- rangement, Fig. This set-up length- ened considerably the range which welder tack welder was aiming, producing favorable psychological effect. The acceptable range stub weights tabulated Table III. Where more than one bundle has been issued and the stubs become mixed, the stub weights covering each individual size must totaled in- dicate the maximum and minimum limits. planning the system, the returned stubs are simply placed the scoop, weighed and dropped into the scrap paint can below. All this accomplished with minimum lost time. 48—THE IRON AGE, April 1943 prevent individuals from dis- carding stubs, the minimum limit was specified. With this figure designated, man not returning his full quota stubs immediately singled out the weight will below the minimum. these cases the stubs must counted. This process requires extra time and not otherwise resorted to. Results Economy Program After this economy system had been for several months, welders who originally criticized bother and waste time ceased complaining and conformed the re- quirements. Results proved LEFT Stubs are weighed this simple scale with multiplying weigh beam. Below the scale blue- print chart contain- ing the data shown elsewhere Tables RIGHT Each welder supplied with container with holders for elec- trodes, chipping hammer and electrode hold- er. Stubs are col- lected the dish- like base. that what time lost saving stubs more than made melting more the electrodes and less frequent trips the dispense rooms. Prior the inception this plan determination the stub loss was made. Stubs were collected and clas- sified size and from this data the per cent weight and the average stub length wasted was determined, see Table IV. Complete electrodes were disregarded this sampling. That these losses are excessive can- not questioned. Two months after the system become effective, similar tests were run the stubs re- turned the metal room, with the results shown Table must emphasized that these figures were determined actual measurements stubs which were not preferentially selected. The sav- ing 15.1 per cent weight 2.2 in. electrodes staggering and accomplished with practically op- stubs. The actual effect this program best indicated the gross con- sumption figures, Table tabulates this information for four week now erag bog per use 408 me ing col the eal Ib. an 3—Random sam- pling stub ends now turned The av- erage length in.; bogey set was in. period before and the economy drive began. Under the new system, 460 welders used 8948 lb. less electrodes than welders before the economy method began. the number welders working equalized, sav- ing 16,130 made per week. This saving has been effected with- out retarding production. contrary, increase 2.1 per cent has been obtained indicated the rise average piece work hourly earnings. (See Table VI). Assuming daily consumption lb. per welder (10 hr. day) 16,130 lb. constitutes the electrodes used keep the 460 welders working busily for hr. price Te. per lb. for electrodes, the amounts $1129.10 per week. the time these data were compiled stubs were being collected rate three four tons week. The scrap value amounted $70 per week, making grand total saving $1199.10 per week. Other Intangible Benefits Over and above the obvious elec- trode saving, other advantages, not easily determined, accrue the benefit this shipyard. First and foremost these the complete elimination from the hulls and platens stubs and odd pieces full length electrodes. Either these items will easily roll when stepped and cause injury. The decks any partially completed hull are covered with cables and other necessary equipment which TABLE Stub Loss After System Was Installed Stub Loss Electrode Weight, Average Stub Size, In. Per Cent Length, In. 11.2 1.5 13.0 1.8 1.8 leave very little space for walking. these places are kept clean, the likeli- hood worker catapulting over side lessened. The situation platens and skids not nearly severe, but unfortunate falls may experienced. Constantly throughout shipyard cleaner-ups are work collecting all kinds metal pieces for removal the scrap yard. Ordinarily electrodes and stubs are mixed together with all TABLE Stub Loss Before System Was Installed Stub Loss Electrode Weight, Stub Per Cent Length, In. 4.3 23.5 3.0 4.5 Average 26.5 3.9 other types scrap. All must separated and classified prior ship- ment. After this system became ef- fective, the task cleaning was greatly facilitated. Stubs now collected central locations and sealed scrap paint cans weighing approximately 100 lb. each, which are removed the scrap yard trailers. These stubs are shipped the steel mills for use Class scrap. New electrodes are delivered the metal dispense rooms truck. The dispense room personnel breaks the commercial lb. packages into the bundles outlined Table Each individual welder supplied with metal container shown Fig. The cylindrical tube ample hold two the largest electrode bundles. The ring dish around the bottom ample space which save the stubs while the bundle being used up. When new electrodes are desired the container taken the metal room and stub lengths are determined previously described. has unused electrodes them from night moisture his tool box. This eliminates the necessity making two extra trips the dis- pense rooms. also allows him start work more quickly morning. Both the electrode con- tainer and tool box were standard welders’ equipment prior inaugu- rating this system. Extra Supervision Electrode economy systems similar this one have been tried before and discarded. One the main dis- advantages has been the increased supervisory and directive personnel necessary reach the desired ends. This all means added expense and subsequent discarding the plan. The advantage this economy sys- tem the total lack supervision necessary once has begun op- erate. additional personnel re- quired and new burden placed the welding department foreman. The system actually maintains itself. Theoretically delinquent welder reported the welding foreman the metal room personnel when his stubs have been rejected two occasions. This places the burden the men actually distribut- ing the electrodes. They must use good judgment their handling individual welders. far the first man has yet reported. The fre- quent cautioning the metal room personnel and their strict adherence the requirements the system have convinced lax welders that they must conform the limits specified. (CONCLUDED PAGE 138) TABLE Comparison Weekly Electrode Consumption Gross Electrodes No. Welders Consumed Earnings Working Weekly Weekly per Hr. Before system 403 50,785 $0.949 0.969 After system 460 THE IRON AGE, April less fter ilar re- the 2.2 op- ‘am ates Nickel Plating Fine Wire continuous plating wire and strip has been the de- velopment stage for several years, but has taken the present emergency complete the cycle its present advanced position the plating industry. Prior the pres- ent emergency the incandescent industry manufactured the filament supports inside the lamp bulb from nickel wire. These short leads and supports consumed times much 50,000 lb. virgin metal every month. The filament support and lead 50—THE IRON AGE, April 1943 port part inside the bulb, the sealing section passing through the glass wali, and the outer end which makes contact the brass shell, center button the base the bulb. These three sections are normally differ- ent metals joined together weld- ing. The part the lead inside the bulb pure nickel, nickel plated wire; the center section iron nickel alloy with approximately the same coefficient expansion the glass shell, while the outside end JAMES CONOLLY Chemical Engineer, Hanover Wire Cloth Co. copper copper coated The upper end the nickel plated wire flattened, and then bent almost flat itself make hook hold the tungsten filament. After the end the filament placed this hook, the hook flattened hold the tungsten filament tightly place. During the past decade, several European companies have been mak- ing these supports from fully an- nealed iron wire plated with nickel, place the pure nickel support. The nickel coating applied the iron wire must have excellent characteris- ACH these five separate cells plates one-fifth the total thickness nickel the wire, and each trolled rheostat and has its own ammeter and voltmeter show that operating efficiently. ° ° } The ire the the ysten veral mak- an- ickel, iron teris- five wire, con- tank its and show ‘ating the wire passing around tension and the spooling table, where wound di- ameter spools. The tension unit pulls the wire through the line constant speed, while the spooling table turns the spools the proper speed for correct winding. ties yield the same results the pure nickel wire. The coating must excellent adhesion sistance the volatilization the iron core the support. the nickel coating does not have this ad- hesion and ductility, the base metal will exposed the formation the hook which holds the filament tightly place. The Hanover Wire Cloth Co., the request several other com- panies, undertook produce this high quality precision nickel plated wire large volume, but with saving nickel formerly consumed. After care- ful study and experimentation, line was designed which the wire kept free from mechanical cold possess This line, shown the diagram, has minimum pull the wire through the line. The wire stock received from the draw- ing mill in. diameter coils, which have been bright annealed give scale-free dead soft wire. These coils are then fitted reels and started into the plating line. The cleaning por- tion the line consists soak cleaner, electrolytic cleaner, pickle with rinses after each operation prepare the wire for plating. The actual nickel plating carried out five separate cells, each one plating one-fifth the total thickness nickel the wire. Each the five cells controlled tank rheostat, and has its own ammeter and voltmeter indicate operating efficiency. After plating the wire rinsed cold water and then boil- ing water that will dry rapidly. The wire then passes around the ten- sion drums, and onto table where spooled in. diameter spools. The tension pulls the wire through the plating line constant speed, while the spooling table turns the spools the proper speed for correct spooling. The line has average daily out- put over 1,000,000 ft. precision plated wire when operated its maximum efficiency. From these production records, appears that the design straight horizontal path for the wire was excellent solution this production problem. plating line for fine wire, which the wire kept free from cold working possible. Uncoiling Cleaner reels plating cells Nickel sump tank Electrolytic cleaner Electrolytic pickle Tension Spooling table unit THE IRON AGE, April = Soak Cold Cold ° { Cold Hot tical axis centrifugal casting show- ing actual paraboloidal cavity com- pared with calculated cavity. casting metal cylin- drical molds spinning about herizontal axis has long been used the mass production cast iron pressure pipe. Both the sand- lined mold and metal mold processes have been successful commercial use for the past years. The eco- nomic soundness these two cen- trifugal processes for making cast iron pipe has long since been proved. good physical proper- ties are obtained virtue cen- trifugal castmg and this has resulted reduction the required thick- ness and weight pipe for given service. Alloy steel gun barrels are centrif- ugally cast horizontal metal molds process developed over long period years Watertown Arsenal. 52—THE IRON AGE, April 1943 Tubular castings various high alloy steels well non-ferrous metals are being produced number foundries very successfully zontal centrifugal casting both metal and sand-lined molds. Such parts wheels and gears are cast centrifugally but usually spinning about vertical axis. For several years there has been gradual but continuous increase the use the centrifugal casting methods for pro- ducing high quality castings, and the present emergency has given sharp impetus the centrifugal casting steel, not only improvement static casting methods for steel cast- ings but also method produc- ing directly from molten metal en- gineering parts cast steel which formerly could made only from forgings, which involves the pouring the ingot, passage through succes- sive stages the rolling mill, and finally the rough forming the de- sired All centrifugal casting effect pressure casting, that the molten metal forced against the mold wall under relatively high pressure, com- pared the usual gravity head static casting. This confers the ad- vantages better feeding, elimina- tion reduction shrinkage cavities and gas pockets, and denser metal. Pressure applied centrifugal force differs from that applied other pressure casting methods that selective its action, the heavier components being thrown outward with greater force than the lighter particles. This helps elim- inate light non-metallics flotation inward toward the axis the rotat- ing molds. When mold containing molten metal spinning about any axis other than the horizontal, the resulting in- terior cavity paraboloid whose shape and dimensions depend upon: The spinning speed; the maximum di- ameter the top the cavity, and the angle inclination the axis revolution. When these three fac- tors are known, the cavity—except modified shrinkage and piping —is exactly determined and may calculated mathematical formulae (Fig. 1). Centrifugal casting with axis vertical used for articles which are generally disk wheel-shaped with hole the center. section through the pa- raboloidal cavity the axis the casting carrying most the shrink- age and non-metallic inclusions, usually bored out finishing. an- other method using centrifugal force about vertical axis, molds for several castings are spaced near the RIGHT 2—Bogie wheel hub castings (No. Table LEFT 3—Ship shaft castings (No. Table |). Centrifugally perim metal the castir zonta the erabl least ing meta mold meta pour tirel yield side with labo ing the be J 4 “4 ‘a ay is” ts q : te r 4 4 | ; | ifugal the hrown tation rotat- nolten other whose upon: di- ly and axis fac- piping mulae with for erally pa- the hrink- ns, an- ifugal for the the spinning flask. The metal poured into down-gate the axis and fed into the separate castings through radial gates. When mold spun about hori- axis the interior cavity formed the molten metal perfectly cy- and exactly determined the mold dimensions and the volume metal poured. This method pref- erable for casting parts which are least having cylindrical interior. vertical centrifugal casting, pour- ing heads are often used feed the metal into the axis the spinning mold, and sometimes gates carry the metal from the axis heavy sections along the perimeter. horizontal centrifugal casting, customary pour weighed amount metal en- tirely into the mold itself that yields per cent greater may attained. making casting with cylin- drical bore the horizontal cen- trifugal method, the core for the in- side is, course, entirely eliminated, with attendant saving time and labor. However, more than one inside diameter required, the larger i.d.’s may formed cores extend- ing from the ends the mold leaving the smallest cylindrical centrifugal force. ° DONOHO Metallurgist, American Cast Pipe Co., Birmingham, Ala. ° ° ° steel both sand-lined and metal molds. Given are product char- acteristics, mold material and mold washes, spinning speeds, metal- lurgy metal, etc. This revision paper presented the Feb. meeting the Steel Founder's Society America. For true centrifugal castings, produced the horizontal method, inspection problems have been found steel castings large the critical defects are subsurface imperfections detectable only radi- ographic other expensive and time consuming methods. centrifugal castings such defects are found are nearly all cases the inside outside surface the casting and thus more readily detectable. Briefly, the chief advantages centrifugal steel castings are: Sound- er, denser, cleaner castings, higher yields, elimination cores, and sim- plified inspection. Disadvantages are: The limitations sizes and shapes adaptable the process, the expense installing and maintaining spinning machines, the increased difficulty changing equipment make variety castings jobbing work. The centrifugal process best adapted the mass production large quantities identical castings and since this also one the con- OBE & = z — ditions which make mold” processes economical, not sur- prising find the two processes com- bined many instances. The choice the mold type, whether metal sand, depends upon number fac- tors which must considered before tooling make new type general, the conditions favorable the use metal molds are: (1) Where very large quantity identical castings are made, (2) where the outside contour the casting simple enough that can readily slipped out the mold, where fast cooling rate from the outside inward, with atten- dant fine grain desirable. Cen- trifugal casting sand-lined molds preferred. (1) Where the metal must flow relatively long distance over the mold surface, (2) where the shape the casting such that the mold must broken down order remove the solid casting, (3) where dimensions and shape similar cast- ings, (4) where relatively uniform cooling rate throughout thick sec- tion desirable. Spinning speeds for castings, course, vary with the size and type casting. For sand- lined molds, general rule use spinning speed which will give cen- trifugal force about times grav- ity. simple formula derived from the centrifugal force formulae give the spinning speed for cen- metal is: 1675 inches. Therefore, for in. di- ameter the r.p.m. 967; or, for diameter, the r.p.m. 684. Spinning speeds near the THE IRON AGE, April 1943—53 LEFT barrel castings (No. Table BELOW hub castings (No. Table Note cored larger TABLE Acipco Steel—Centrifugally Cast 54—THE IRON AGE, April 1943 (Castings made spinning about the horizontal axis) pipe; tubes cast centrifugally (No. Table flanges welded on. the above formula, have been generally best, particularly for initial spinning speed during ing. Although centrifugal fore will theoretically hold the the wall the mold the higher fore desirable squeeze out slag par ticles and lighter non-metallics. Als with speeds much less than the give force gravity the metal will not “pick up” readily slipping “raining.” high spinning speeds will tend cause longitudinal hot tears reason the circumfer ential tension developed the trifugal force the casting freeze and begins shrink away from mold wall. metal mold centrifugal casting spinning speeds somewhat lower that the calculated may used since the chilling effect the mold causes the metal “pick up” more readily than the refractory sand mold. For very thick castings, the initial spinning speed often slightly increased above the calculated speed order Pour Maximum Minimum Total Casting Steel Mold Time, Mold No. Casting In. Length, In. Weight, Lb. Type Type Sec. R.P.M. Bogie wheel hub SAE 1030 Metal 950° Ship shaft ft. 2500 SAE 1030 Sand 1100 ody Retort tubing ft. 2200 28-15 Stainless Sand Hawse pipe tubing 21.8 ft. 3500 SAE 1030 Sand 525 Cylinder barrel 110 SAE 4140 Metal 850 Flanged weld neck 300 SAE 1030 Sand 1100 Flanged weld neck 150 SAE 1030 Sand ig 3 s ° ° ° 4 7 = 4 4 4 quickly up” the larger volume metal. For castings, such flanged castings, where the maximum O.D. very much greater than the minimum the diameter which base the spinning speed may ficient centrifugal force the I.D. and yet not excessive force the maximum the steel foundry Acipco (American Cast Iron Pipe Co.) variety steel castings are produced centrifugal methods both sand- lined and metal molds. While steel found fore tal fore par speed metal the than ce the than began 1940, cen- very trifugal casting inning grey cast iron pres- above sure pipe has been tice since 1922. much 15,000 tons centrifugal cast- ings per month has been the usual out- put for the past sev- eral years. The steel foundry served five acid lined elec- tric are furnaces, one 6000 lb. ca- ‘pacity, two 4000 Ib. one 2000 lb. capacity, and 500-lb. furnace used largely for experi- mental purposes. six day, two shift basis this foundry ABOVE neck castings (No. 10, Table LEFT 8—Battery horizontal ner heads for metal mold casting inder barrels. BELOW the steel for one cylinder barrel cast- ing. capable producing 1500 tons per month salable product. the operation the furnaces, preliminary carbon samples are run Leitz carbon meters, two instru- ments serving the five furnaces. Fin- ished heats are tapped into tea-pot ladles which serve holding ladles and for pouring into the individual casting ladles. analysis final samples from each heat carbon, sul- fur, and phosphorus are determined the chemical laboratory while sili- con, manganese and alloys are quan- titatively determined 56—THE IRON AGE, April 1943 ABOVE Pouring the weighed amount steel into the spinning mold. RIGHT IG. pouring. BELOW Extract- ing the solidified casting. graphic laboratory analysis for elements carried out from the pouring the sample with plus minus per cent. and show some the castings reg- ularly produced the horizontal cen- trifugal method and Table gives the salient casting data. Bogie wheel hub castings, cylinder barrel castings and other relatively short length cylindrical steel parts are cast Acipco metal molds spinning about the horizontal axis. The engine cylinder ca