The Iron Age 1943-07-29: Vol 152 Iss 5

29, 1943 Put experience your mill roll necks with Timken Bearings There short cut experience—and substitute for it. This has been demonstrated time after time the application roller bear- ings steel mill roll necks. result our many years experience the design and manufacture roller bearings for roll neck service long ago eliminated all guesswork and cut-and-try methods. Thus, know advance what can expect- any Timken Roll Neck Bearing installa- tion—in high tonnage rolled; low bearing cost per ton rolled; power saving; and maintenance reduction. Why experiment? The Timken Roller Bearing Company, Canton, Ohio. | a 2 inet? img All day today and Straight through every minute the hours your Cleveland Worm Gear Speed Reducers stand competent guard—they deliver depend- able power keep equipment going, come what may. That’s what they’re built course—yet Clevelands’ almost endless capacity absorb punishment and keep driving ahead one the things that the oldest customers mention most often with greatest appreciation. quote from just few:— “Our Cleveland Units have run hours day for years ... have never opened the products industry. “Twenty-four hours day beginning 1929—our Cleve- lands get special metals. “For nearly years Clevelands have given uniform operation, minimized and brass. and night since 1923; Clevelands insure uniform cement. THE IRON AGE, published every Thursday the CHILTON CO. (INC.). the clock for years—Clevelands keep our equipment going”—mechanical rubber. “Our equipment must run continuously—Clevelands have prevented shutdowns here for more than industry. Designed and built for peace, Clevelands today are doing big wartime job. Count them stand you always—all day today, all night tonight. The Cleveland Worm Gear Company, 3252 East 80th Street, Cleveland Ohio. Affiliate: The Farval Corporation, Centralized Systems Lubrication Canada: PEACOCK BROTHERS LIMITED SPEED REDUCERS Entered second class matter November 1932, the Post Office Philadelphia under act March 1879. yearly North America and South America, Foreign $15. Vol. 152, No. “ J. H. VAN DEVENTER Editorial and Offices East 42nd St., New York Y., Vol. 152, No. July 29, 1943 Johnson, Market Research Hoyes, Production Manager. Business Man Writes About Business Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. 1016 Guardian Bidg. 428 Park Automatic Metallic Arc Welding Silica Gel Prevents Engine Corrosion ve. . Residual Stresses Welded Structures New Data Sand Behavior (Incorporated) New Equipment—Finishing Chestnut and Sts., OFFICERS AND DIRECTORS atures MUSSELMAN, President News Front VAN DEVENTER Vice-President West Coast BAUR Vice-President Fatigue Cracks JOHN BLAIR MOFFETT, Secretary Editor JULIAN CHASE THOMAS KANE HARRY BUFFY CHARLES HEALE our ° fe] nds Member, Audit Bureau Circulations News and Markets DPC’s Huge Investment Analyzed Aluminum Industry Promising Position day New Magnesium Foundry Adds Capacity New Can Order Poses Difficulties all Member, Associated Business Papers Detinning Personals and Obituaries Machine Tool News 116 Metals News and Developments 118 Non-Ferrous Metals Prices; Scrap Prices 119 Iron and Steel Scrap News and Prices 120 Comparison Prices Year 122 Finished Iron and Steel Prices the Industrial Arts Index. Steel and Warehouse Prices 124 or merica, Ou merica an Possessions, $8; Foreign, year. Semi-Finished Iron and Steel Prices 125 Single Copy, cents. Annual Number, $2. Pig 128 Ore and Coke Prices 129 Ferroalloy Prices ° ° ° ° ndex Advertisers 171 & al CONCERNING WARTIME VACATIONS The terrific pace war production continues—and with metals still the critical list—men who buy are under greatest pressure. But brief periods mental relaxation are still essential health and efficiency. So, the interest your country, your company, your family and should take some time off this summer. True, travel restricted. The boys the Service have priority transportation and God bless them. But happy vacation really doesn’t depend distance—so plan ahead—leave your worries behind and soak some good old sunshine. And—as far steel concerned—tell your men depend Ryerson. Our stocks are still the most complete. And where war requirements have created some shortages, can usually offer substitutes that will the job well. ahead—enjoy yourself. JOSEPH RYERSON SON, INC. CHICAGO MILWAUKEE ST. LOUIS CINCINNATI DETROIT CLEVELAND BUFFALO BOSTON PHILADELPHIA JERSEY CITY RYERSON 30—THE IRON AGE, July 29, 1943 ~ ESTABLISHED 1855 VAN DEVENTER President and Editor BAUR Vice-President and General Manager DIX Manager, Reader Service ° ° Managing Editor LIPPERT News, Markets Editor JAMES Art Editor... WINTERS Associate Editors MacDONALD BARMASEL BUTZNER Editorial Assistants SCHIEN WILLIAMS BUTTERS Regional News and Technical Editors CAMPBELL Pittsburgh 428 Park PHAIR Chicago 1134 Otis Bidg. MOFFETT Washington National Press BROWNE Washington National Press Bidg. LLOYD Cleveland 1016 Guardian Bidg. BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT McINTOSH Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle Business Man Writes About Business HEN man bites dog, that’s news.” When business man writes book about business, that’s news too these days when most books about business are written people who have never had first hand experience it. Personally, have always preferred read books, fiction excluded course, that were written authors who had first hand information concerning their subjects. Perhaps that the prejudice due engineering education. But would suppose too that medical student would prefer get his anatomy from doctor rather than from poet pawnbroker. Many, many books, most them condemnatory least critical have been written about business during the past few years econ- omists, lawyers, politicians and professors, none whom have had even smattering experience the subject which they write. This has distinct advantage from the author’s standpoint and perhaps from the readers’ too, since unfettered imagination can bring the fascination fiction subject where limitation facts might make more prosaic reading. refreshing, therefore, find book written about business man who thoroughly familiar with and yet who tells the story its function democratic society extremely interesting way. refer “The Spirit Enterprise” just from the press Charles Scrib- ner’s Sons, written Edgar Queeny. Mr. Queeny well known many our readers the president the Monsanto Chemical Co. St. Louis, and one America’s out- standing industrialists. His book should the hands every busi- ness man who believes the dignity and usefulness his occupation and also the vastly greater number hands those who have been misled into believing that private enterprise incorrigible public offender. “The Spirit Enterprise” not one sided book. not written defense capitalism nor attempt whitewash those that have grown into through the distortion its principles selfish interests. exposition, the contrary, and very convincing one, what American capitalism has done for our Amer- ican people and what greater things can the after-war future imbue with the true spirit enterprise. One who has read the “anti” works Marx, Thorstein Veblen and Stuart Chase, whose grasp practicalities indicated their sponsorship the pseudo “Doctor” Scott and Technocracy will find refreshing hear from man whose writing and reasoning are based fact instead speculation. Mr. Queeny does not share the belief some that necessary abandon the social aims the New Deal. Nor does think that industrial management whole does either. does believe however that these objectives are unattainable through regimentation extension bureaucratic control enterprise and that the one hope attaining them, together with better standard living for all through unshackling the spirit enterprise and encouraging honest competition. | | | ° ° 4 | | | News Front Steel industry average May, 1942, was hr.; total employees were 548,000. The work-week climbed slowly level May, 1943, and total ployment dropped 522,400, with average weekly earnings $49.12. Steel production lifted sharply the May 1942-May 1943 interval, and the 26,600 drop employees was the result not only longer work week but also shift from production highly finished steel. June the steel industry lost about 279,000 tons ingots, compared with May tons because the coal strike, about 148,000 tons because repairs and breakdowns, particularly severe during WPB shortly will issue directive further restricting the use stabilized (Type 547) stainless steel, forcing more borderline tonnage the stabilized alloys. Electrolytic tin plate now accounts for 133 per cent total tin plate output, having doubled percentage-wise and tripled tonnage-wise since January. And: Mills are striving lift efficiency electrolytic tin plate lines from current per cent average somewhere around per cent. Further improvement strip cleaning expected reduce the excessively high percentage waste plate. While WPB and Government officials rant against civilian complacency about the war and industry's post-war shenanigans, the average sentiment around WPB itself just about identical with what being condemned. The stainless steel frozen inventory total has dropped from 18,000 tons down about 12,000 tons, which about 1000 tons thin, narrow, per cent chromium auto trim strip, the remainder being pretty much Steel Recovery Corp. now less inclined guard this stock stainless for its alloy content, view the current incomplete utilization stainless scrap the market. Therefore: Rules will eased for utilization this stainless stock, particu- larly aircraft and even for some uses questionably essential the war effort. The 12,000 tons will likely cleaned months. industrial quarantine provide additional manpower for Boeing Aircraft being slapped the Seattle-Tacoma area. Six small manufacturers and boat builders have had Army contracts cancelled and others have been warned move from the area the axe will fall. Boeing's wages are stabilized below the area's average. Personnel problems Alcoa's Cleveland plants have been completely delegated the union (CIO Mine Mill and Smelter Workers), following months high turnover and spite fancy regulations, ferrous turnings are still sorry state, with producers frequently finding market and way comply with WPB orders that turnings move. Proposals that steel mills install crushing and briquetting equipment are meeting stiff opposition. German analyst writing recently Stahl und Eisen said American steel capacity and production were given bogus lift shifting reports from gross ton net ton basis. said the move was dictated desire for more impressive propaganda figures. Powder metallurgy now offers large field for the manufacture copper and powders electrolysis and possibly plating metal powder parts cover Jobbers handle about per cent the steel tonnage, but west the Rocky Mountains the jobber tonnage jumps per cent the total, and over per cent the wire products and tubular tonnage that area handled through jobbers and distributors. When foremen the Ecorse plant Murray Corp. America recently went Strike, workers continued production uninterruptedly, without supervision. Renegotiation air raid damage payments has become German practice. With factory inspectors falling behind their estimating, companies applying for damage are Ceiving advance payments subject adjustment. New designs for infra-red reflector equipment and new application techniques will make possible temperature ranges excess 1000 deg. ~ 7 are ayer OMMERCIALLY, plasticity re- fers the ability certain materials pulled pushed into useful shapes. Many metals, iron, copper, aluminum, nickel, silver and many their alloys are plastic their frozen crystalline state. These and other metals, glass, sili- cones, natural and synthetic resins, are plastic (forgeable, form- able) their heated state. Other materials are plastic shapeable when moistened with suitable solvent putty, plasticone and paper (moistened with water). The materials having characteristics plasticity these three plastic described, order, crystoplastic, thermoplastic and solu- plastic. Thermosetting and solusetting ma- terials should also distinguished here they interlock closely many respects with plastic materials but for practical purposes they lack plasticity. general these are mix- tures fillers, flow aids and setting adhesives, powdered for mobility. the presence heat solvent they undergo chemical reaction change which solidifies sets the binding _adhesive. reason the chemical change they cannot made plastic for further change shape. Typical thermosetting materials are the common phenolic (carbolic acid and formaldehyde) resin binders mixed with lubricating plasticizer and such fillers wood, flour as- bestos for compression heated dies; mixed with alcohol and other solvents and impregnated into paper, cloth plywood, then baked flat shape under similar heat and pressure. The sulphur re- rubber molding and the copper-tin reaction the sintering (baking) the molded powdered bronzes also qualify such processes thermosetting. Portland cement the binder with sand filler and water the solvent may typify the solusetting process. “Cold molded” electrical parts, tiles, paints, are widely different ex- amples solusetting materials. Sub- sequent surface fusion glazing pressure formed ceramic clays operation. should also distinguish the term “coldset” materials this descrip- tion sometimes applied themo- plastic materials because after addi- tion heat make them plastic they must cool resolidify. Perhaps cohesion and adhesion are useful help distinguish the plastics and the setting mixtures. thermo- setting and solusetting methods the added bonding agent adhesive creates surface attachment means combination. Among the plastics, the other hand, mutual cohesion molecules The material this and succeeding articles will eventually appear the book “Plastic Working Metals and Non-Metallic Materials,” published John Wiley Sons, Inc., New York. This will the third edition the standard reference work, “Plastic Working Metals and Power Press Operations,” Crane. 34—THE IRON AGE, July 29, 1943 ° ° CRANE Chief Development Engineer, Bliss Co., Brooklyn complex) permits re- arrangement and reestablishment “electro-magnetic” bonds the plas- tic range. Solubility Common salt, which described soluplastic, will into solution water certain per- centage. Its molecules tend dis- perse comfortably among the water molecules until they become crowded, when they crystallize out super- saturated solution, until the water evaporates and they again cohere amongst themselves quite tenaciously. Gold and silver dissolve each other when molten any percentage, but interest that the intermediate alloys (when cold) are less plastic than either the pure metals.’ Iron carbide dissolves iron 0.83 per cent. Substantially (deep drawing steel) found plastic cold working operations about per cent reduction. Iron carbide dissolved iron (dispersed through pearlite) strengthens the steel interference with slip plane movement’ the cold plasticrange. Another interesting quirk solubility illustrated copper and Alpha brass having Crane, John Wiley Sons, Inc., Fig. 12, 15, second edition. Ditto, Fig. 117, 122 and Fig. 122, per cent zinc dissolved cop- per has considerable cold plasticity. Beta brass, the other hand, with solved copper, suitable only hot forging (thermoplastic). Further increasing the zine percentage results chemical compound Cu, Zns whic ing, men mus thei and ice its deb mol the the fibe ver ers pla he: thi pli tin ste tic sh lin Ss which too brittle for work- ing, either hot cold. Temperature and Plasticity Many elements, compounds ele- ments and mixtures (all which must distinguished) change their temperature rises through more less familiar states solid. through “plastic”, liquid, vapor and gas. Water, varying from solid ice liquid steam, familiar, but its moldability the slushy stage debatable, unless consider snow- balls and ice cream. Among the com- mon “thermoplastic” hydrocarbons, the lowly paraffine candle will mold itself into some sad shapes hot day. However, cold day the candle not plastic and will break. Typical some syn- thetic molding mixtures, asbestos fibers finely divided wood with pul- verized thermosetting resins for bind- ers and tale oily lubricants plasticizers, are mobile rather than plastic the time that setting heat applied. The mixed mass hot plastic only during the extremely brief setting period. The speed this reaction has delayed and com- plicated the application thermoset- ting materials injection molding. Two periods plasticity are note- worthy some materials. Thus, com- mercially pure iron (deep drawing steel), aluminum, copper, nickel, lead and some their alloys are sufficiently simple crystal pattern arrangement that they may cold worked the crystalline state below their annealing recrystalliza- tion temperatures. Secondly, they may hot worked the amorphous state increasing atomic distances and shifting interatomic bonds between the crystalline and fluid states. The limiting temperatures this thermo- plastic range may relatively wide, for beta brass relatively nar- row, for copper. Lead normally worked its hot range anneals normal room temperatures. Note also that zine, tin and magnesium are thermoplastic only for practical purposes, their crystal structures are too complex for appreciable slip plane movement. However, tin an- neals below room temperature and and magnesium require com- paratively little added heat give their atoms sufficient mobility for plastic change shape. Among the synthetic resins. cel- lulose acetates and methyl methacry- lates are both thermoplastic and the latter appear have appreciably wider hot working range which gives the operators more handling time. Recognition the several states plasticity makes possible show that the press working methods mass production follow rather simple rules throughout the expanding range engineering materials, whether they metallic, organic ceramic. Materials are workable and reworkable the crystoplastic, soluplastic thermoplastic states. Other combinations enjoy brief mobility process through thermoset- ting solusetting change. interpreting the workability plastics terms the plastic working metals, Mr. Crane begins this series articles showing how the material and its state governs the com- bination working pressure, temperature and time allowance required produce particular shape. the second article, will discuss the hasic chemistry various plastics. Fig shows relative temperature- plasticity relationships for two types Below the hot plastic range the methyl methacry- lates become brittle, Fig. but the cellulose acetates, Fig. show combination elasticity and limit- plasticity down below room tem- peratures. room temperature, the elastic spring-back the latter high offset most cold forming. Thus, within the elastic limit the surface material, Lumarith cellu- lose acetate) may bent radius about times the sheet thickness, whereas deep drawing steel would limited radius about 1100 times its thickness 1/15th the spring-back. flow temperature, showing that some thermoplastic materials may worked through wider and less sensitive tem- perature range than others, though possibly other properties. Cour- tesy The Dow Chemical Co. Elasticity and Plasticity have con- siderable inter-relation both the cold plastic and the thermoplastic range, with consequent interesting effect upon plastic working opera- tions. The elastic limits bronze, copper and steel, for example, are increased the metals are cold worked and strain the same time, the remaining plastic range these materials becomes progres- sively less until annealing and re- crystallization becomes necessary. The elastic movement represented stress-strain diagram the nearly vertical increase load without ap- preciable yielding the material. The subsequent substantial compres- sion stretch the material with Average flow saran Average flow cellulose thermoplastics molding range saran Temperature molding cellulose thermoplastics molding range saran and cellulose thermoplastics THE IRON AGE, July 29, P= 0 ° ° r- it tA 1s 2, ° ° ° = S- ls Tensile stress, per load cross head speed 0.3 inch per minute t | + Elongation, per 36—THE IRON AGE, July 29, 1943 2—While breaking without distortion and with increasing elastic limit below 100 deg. F., Lucite shows considerable plastic range with some remaining elastic recovery when warmed 140 deg. recommends 248 280 deg. for simple form- ing, 300 deg. for curve forming, 305 350 deg. for compression mold- ing and 370 475 deg. for injection molding. Cour- tesy Plastics Dept., Pont deNemours Co. 3—Approaching crys- high elastic limit 320 deg. Lumarith (cellulose acetate) indicates increas- ing plastic range and de- creasing elastic recovery temperature rises. For such material working tempera- tures recommended are: Forming, 275 280 deg. F.; compression molding, 260 390 deg. and injec- tion molding 340 450 deg. Courtesy Celanese Celluloid Corp. moderate change applied force rep- resents plastic movement. Now return the thermoplastic range, strain curves for synthetic different temperatures met- als. The sudden termination the elastic curves the lower tempera- tures shows clearly their lack plas- ticity the crystalline state and the differences their freezing points. Fig. shows the lowering elasticity the temperature increases, although the curves have not been carried down the producer’s recommended form- ing temperatures the semi-fluid injection molding die casting tem- perature. The dip the cooler curves indicates change directional strain resins ‘For steels see Table XNI, p. 262, Plas- tic Working Metals—Crane. *See Figs. 15, 123 and 185, ditto. the structure. The subse- quent rise shows work hardening, and would eliminated slower move- ment tensile pulling sufficient time for stress relief. The Lumarith curves (Fig. also indicate why the higher temperatures (275 280 deg. F.) are recommended for forming. Obviously work harden- ing and resistance will less and capacity for flow rearrangement will greater. Also, with lower elastic range lesser holding stress relieving period will required while molecules ease themselves into set the new positions. sure, similar spring-back tendencies are found among the metals, but due lower elasticity thereof they are neg- lected, allowed for, corrected. Thus V-die bending operations squeeze bottom stroke sets compressive stress counteract remaining tensile strain the sur- face fibers. Structure and Plasticity Modulus elasticity being some- what misnamed sometimes misleads us. rather modulus mea- sure rigidity. The modulus elas- ticity for the metals the mil- lions; for synthetic plastics, many times more elastic than steel, down the hundred thousands; and for the rubbers, stress-strain curves indicate way down the hun- dreds. Even when the modulus constant for the steels, the maxi- mum stretch elastic deflection (elas- tic limit modulus elasticity) may vary widely between an- nealed iron and dispersion hardened tool Here again deflections are materially greater, through widely variant, among the synthetic plastics, 11000 6000 | | | | | n rep- resins met- the d the 10ugh down form- i-fluid tem- urves Plas- and icient also ended rden- and lower stress while sure, are neg- sur- leads mea- elas- mil- nany and hun- elas- city) an- ened are idely and greatest among the related elas- tomers. Pure metals and solid solution al- loys, such alpha brass, are mona- tomic, one atom per molecule. Com- pounds combine several atoms per molecule. Thus, iron carbide FesC combines three iron atoms and one carbon atom into molecule. Cellu- lose triacetate combines carbon atoms, hydro- gen atoms and oxygen atoms into complex molecule having molecu- lar weight nearly six times that iron yet large and spaced far apart that given volume weighs less than one-sixth the same volume iron. Freezing into crystalline form, the intermolecular forces tend es- tablish orderly and balanced ar- This orderly arrange- ment may disturbed and unbalanced the extent permitted the (crys- to) plastic range the material. Internal stresses may then re- lieved and orderly crystal structure annealing adding heat that electronic energy activity increases such point rotate the molecule again into rela- tion with those around it. The order- internal structure annealed metal makes more dense than disturbed, cold-worked metal. Simi- larly Fig. shows that recrystalliza- tion worked thermoplastic resin (vinylidene chloride) also increases its density. Recrystallization tempera- Fig. 14, Plastic Working Metals. Fig. 117, 122, ditto. Fig. 127, 135 and Fig. 180, 198, ditto. ture affected some extent the time allowed (Fig. and section thick- ness. the temperature raised above range and jnto the forging hot-working range, annealing soon becomes prac- tically spontaneous only mechanical considerations (ease and freedom movement) limit the ex- tent working. Atomic activity has then reached point permitting molec- ular masses moved about quite freely although not yet fluid (molt- en) flow gravity. This free- dom from molecular regimentation the thermoplastic range has also been referred the amorphous state. RIGHT Molybdenum powder cold pressed 60,000 p.s.i. then above its temperature permit improvement interatomic relations and finally plastically worked swaging and wire drawing with intermediate an- nealing correct interatomic strains. Courtesy Goetzel, Amer. Electro Metal Corp. and Amer. Soe. for Metals. specific gravity vinylidene chloride during recrystalliza- tion from the mixed arrangement the worked thermoplastic state (1.66) the close packing the crys- talline state (1.692), improving further with time for crystal grain growth. Cour- tesy Goggin and Lowry, The Dow Chemical Co. quired different temperatures cause zation lecular stress read- justment viny- lidene chloride (Saran). This recrys- tallization range typical also the metals. Courtesy Lowry, Dow Chem- ical Co. 0.1 Temperature, CREEP STRENGTH 100 120 160 180 200 220 240 260 Days THE IRON AGE, July 29, 1943—37 Time, hours deg.F. 100 0.024 600 per 0.05 Wall thickness 004 Wall thickness Ing pressure Wall Work Temperature, deg. 200 225 1G. 7—As the metals, strength vinylidene chloride tubing remains substantially constant the crystalline state, but reduced with increasing temperature the amorphous thermoplastic range. Courtesy John Delmonte, Plastics Industries Tech. Inst., Machine Design. oO Permanent set, per cent Temperature, deg. 8—Five thermoplastic materials show increasing rate creep they pass recrystallization temperatures. The rate remains more constant for thermosetting phenolics deterioration temperatures. Load and time were constant. Courtesy John Delmonte, Plastic Industries Technical Institute, Machine Design. 38—THE IRON AGE, July 29, 1943 Pressure-welding powders thermoplastic materials, both metallic and organic, takes advantage in- termolecular attraction for bonding purposes. Distinction should noted between similar fragments and the bonding powder mixtures which some pow- ders are bound together other con- stituents introduced adhesives binders. Pressure Welding Characteristics The four essentials pressure- welding are (1) intimate contact (2) clean particles (3) suitable temperatures within their thermo- plastic range and for (4) sufficient time, Fig. permit adjacent atoms molecules improve their relative alinement and establish cohesive welding can occur almost instantly beween particles steel shaft steel draw die when the insulating film lubricant breaks down. Pres- sure above the yield point the ma- terial assures intimate contact. Fur- ther improvement may accom- plished mechanical working the mass, forging granules into even more uniform compactness and filling cavi- ties which molecular atomic forces could not close. Oxidation sur- faces forms an_ against forming molecular bonds and accordingly protective atmosphere enclosure usually required dur- ing the welding sintering period. Where porosity desired the par- ticles need only join random points contact. However, voids among the cohesive particles may reduced pressure substantially elim- inated plastic working during between applications heat for recrystallization. lead and tin recrystallize below atmospheric tem- peratures, reported that their without added heat pressures down 500 lb. per sq. in. Tungsten outstanding commercial example converting from powder pratically flawless, ductile wire though temper- atures extremely high. Fig. indicates the progressive steps the conversion molybdenum powder drawn wire four times dense. The density plotted show elimination voids and gradual ap- proach toward perfect atomic pack- ing the crystal space lattice. Along similar lines and more familiar sheet metal workers are the compari- sons Table which are shown iron e stre tou ing sa se er Wi 1000 250 in- onding noted ling pow- ves istics act 1ermo- atoms hesive ssure- tantly aft eet lating Pres- ma- Fur- the more forces arrier and dur- eriod. par- points mong duced elim- ficient. tin tem- their relded down ically emely enum show ap- pack- Along experimental steps and changes properties conversion copper and jron particles ductile form. Fig. shows how electron activity and intermolecular ties, changing with temperature, effect the mechanical strength typical “pressure-weld- ed” thermoplastic. The material synthetic resin, vinylidene chloride polymer, extruded from heated pow- der and stretched into tubular form. The solidly frozen crystalline state exists below about deg. the temperature increases, the material becomes softer and more easily changed shape. Methods producing the resin permit varying from flexible, moderately soluble material having softening point approximately 158 deg. hard tough thermoplastic having soften- ing point 350 deg. more. Soft- ening points here refer particularly approach fluidity favorable compression and injection molding. Creep Fig. compare the range softening decreasing strength with the range increasing creep for the same and other materials Fig. Here, cantilever beam specimens several thermoplastic resins and one thermosetting resin acting bind- were stressed for four days 1000 lb. per sq. in. maximum fiber stress, followed four days recovery. Creep and the thermoplastic state are obviously coexistent, for when the in- termolecular forces are weakened even the lower part the range, moderate force acting over suffi- cient time will gradually cause change shape excess elastic recovery permanent set). Lead pipe and lead roofing creep the course years, for lead also the lower part its thermoplastic range at- mospheric temperatures. Rate creep thermosetting ma- terials more constant (Fig. limiting temperatures (about 212 deg. F.). Fig. showing time and relations for laminated phe- nolic thermosetting material would also seem indicate ultimate de- crease the rate creep. While this might traceable part taking slack better alinement fiber chains (see Figs. and 12, Part II) the coincidence time different loads might also suggest time limit the stability the plas- ticizer used this Speed Flow line state and thé fluid molten state, Degree working 9—Creep canvas base laminated phenolic thermosetting material two different loads. Courtesy Westinghouse Electric Mfg. Co. the flow thermoplastic materials (metallic organic) varies from creep, comparable glacial move- ment, the almost turbulent flow injection molding. Fig. tests were run two different testing ma- chine speeds (slow compared com- mercial operation) which illustrate effects speed upon and upon strength which, course, also the resistance the material offers flowing changing its shape. has been demonstrated rolling again that resistance increases with Metals—Crane. See Fig. 233, 263, ditto. 209, Working speed the thermoplastic range certain point. any particular temperature this variation depends upon the time required stress- relieve equalize the bonds between TABLE Effect Alternate Compression and Recrystallization Properties Copper and Iron from Powdered Metals Sintered, 1470° 7.90 16,000 9.5 Repressed, tons/sq. 8.39 22,200 4.0 Cold rolled, 25% 37,300 4.0 Reannealed, after reduction. 8.35 17,000 16.5 Cold rolled, 50% 109 2.5 Reannealed, after reduction. 8.59 22.0 Cold rolled, 8.80 117 1.0 IRON Sintered 1830° 6.68 ,000 10.0 Resintered 1830° F., 7.23 34,900 20.5 Cold rolled, 7.39 107 §0,500 2.0 Cold rolled, reduction....... 7.67 133 1.0 From “Plastic Deformation,” Goetzel, Amer. Electro Metal Corp. “Powder Metallurgy,” Amer. Society for Metals, Cleveland, 1942. _ THE IRON AGE, July 29,, ° Cc — molecules indicated Fig. The work done upon these bonds forced change shape generates heat proportion the speed. Extrusion copper tube from cold slug, works commercially fast crank presses because sufficient internal heat ‘generated correct inter- atomic strains and turn out substan- tially annealed material despite about 1000 per cent elongation. Speed also essential many hot forging and plastic forming operations, Lu- cite bomber nose sections, complete the operation before the blank chills. other materials, the lower end plastic temperature range, speeds severe forming operations may have reduced avoid frac- ture permitting stress relief keep with the strain applied. (To continued) inch per minute 6000 inch per minute 4000 Elongation, per cent 130 140 temperatures within the thermoplastic range (of methyl methacrylate) increased testing speed results higher yield point, greater resistance plastic flow, and greater elongation point fracture. From DuPont Lucite data. Leather V-Belts Introduced NEW application flat, full leather contact with pulley sheaves has been put V-belt the Charles Schieren Co. indicated the illustrations, flat leather side walls sheath laminated leather core. high coefficient friction developed the tenacious grip the flat leather walls and makes slack running possible with attendant economies wear both V-belts and bearings, without power loss through slippage. reason the ability splice the belts the machines, the dis- changes and adjustments have been largely eliminated. Furthermore, the need for large and costly belt inven- tories eliminated. Heretofore, was necessary using ordinary end- less V-belts carry stock mul- tiple sizes various lengths for each size, depending upon the variety V-drives operation. Schieren V-belts are supplied long rolls. When new belt needed, the predetermined length 40—THE IRON AGE, July 29, 1943 cut from roll the cross-section required and splice made with the special equipment provided. This consists miter box for preparing feather bevel with ordinary carpenter’s saw, and adjustable clamp. applying cement the joints and clamping, the belt made endless few minutes. The tradi- tional salvage value flat leather belting carries with the new V-belt. Short pieces may spliced make belts re- RIGHT YPE adjustable clamp used splice leather more elaborate type able for longer and larger section belts. ° ° LOWER RIGHT REPARING the feather bevel special miter box preparatory ing leather V-belt. LEFT new Schieren leather V-belt, showing the flat leather side walls, per- mitting advantage taken the well known frictional prop- erties full grain leather. quired lengths kept for repair pur- poses for belts broken through care- lessness accident. Two years service tests under strenuous wartime requirements have disclosed the effectiveness the new leather V-belts. Even oil soaking has not lowered their efficiency, claimed. 9000 8000 ing ma | | an pre | me as | We co) flow, pur- care- inder have has Arc Welding Specialist, General Electric Co., Dallas, Texas YITH the critical shortage skilled are welding operators and the need for fully utiliz- ing existing welding equipment, auto- matic metallic are welding playing ever-increasing part our war production. Phenomenal increases welding speeds over hand welding methods are being reported, with the output per welding operator increased much 500 per cent some welding jobs. Tabulated below are some the war products which the more common automatic metallic are weld- ing processes are being used fully save time, reduce costs and improve weld quality: A—Bare lightly coated electrode coils: Submarine net floats Trench mortar projectiles Bomb casings Machine gun water jackets Depth charge casings B—Extruded coating electrode cut lengths: Shell casings Machine gun water jacket housings C—Heavily coated electrodes coils: Tank wheels Pressure vessels Destroyer turbine diaphragms Boilers D—Atomic hydrogen process: Rifle cartridge clips Aircraft tubing Truck axle housings Accumulator shells Propeller blades E—Submerged melt welding process: Deck plates Bulkhead stiffeners Tank transmission housings Not all are welding jobs, however, Automatic Metallic Arc Welding The author reviews the various types automatic metallic arc welding equipment, and points out the economic and technical factors relating their application. should done the auto- matic process. order determine whether particular job may done successfully with automatic are weld- ing equipment, the part must first welded successfully hand. also must meet the ments: 1—Welds must consist straight seams circular seams. order realize fully the sav- ings possible with automatic welding, necessary keep the are going many minutes out every hour possible. the seams welded are short, many cases the time re- quired set the job will more than cancel the savings made possible the higher welding speeds the automatic process. Also, since the automatic welding head must either move over the work the work move under the head, general neces- sary limit the joints welded straight and circular seams Fig. follow irregular shapes, but most welds this kind can better made hand. 2—The fit-up between the parts welded must uniform and close. The automatic welding head travels uniform speed, uniform di- rection and holds uniform arc length. Obviously, cannot hesitate when comes portion the joint where the fit-up poor the joint not regular. Conditions such this will frequently result poor welds and will require patching hand. 3—The parts welded must positioned that the welds are made the flat horizontal position. already mentioned, the auto- matic welding head traverses the joint and holds certain uniform, preset con- ditions. This precludes the possibility making welds the vertical overhead position where sary manipulate the are the weld made. 4—Production parts welded automatically must large and restricted similar identical shapes. Since most joints require special positioning, turning clamping de- vices, production must enough justify the expenditure for this special equipment. Once welding job has been an- alyzed and found meet all the above requirements, then neces- sary determine which the several available automatic metallic are weld- ing processes should used. Fre- quently, this can determined easily through analysis the base metal cations which must met. Most THE IRON AGE, July 29, ° ° ° ° ° ° | the armament, ships and war products now being arc welded are covered definite specifications assure uni- form product from all contractors. Application Bare Wire the code specifications are not particularly rigid and the main re- quirement the welded joint that air water-tight under rela- tively low operating pressures, bare lightly coated electrodes are fre- quently used. Although such welds are often porous, this obstacle unless necessary grind the surface the weld and expose the porosity. The design some welded structures such that the welds lie along the neutral axis where they are gubject relatively small stress, even the case shock loads. addi- tion, well-made joint, using lightly coated electrodes, may show only points less ductility and only slightly less ultimate tensile strength than the corresponding weld made with heavily coated electrode. the physical requirements the weld are rather high and the base material mild low alloy steel, automatic welding equipment using extruded coating electrode cut lengths, heavily coated electrode coils the submerged melt welding process will required. Automatic welding equipment de- signed use the standard cut lengths ing used principally for making short welds where the complete joint can made with single stick elec- 42—THE IRON AGE, July 29, 1943 3 ABOVE arc- welding equipment being used fabricate automotive ings. With this equip- ment, electronic control used feed the elec- trode into the welding arc preset rate manually. RIGHT 2—Stick electrode feeding attachment applied automatic bare wire welding head for making high quality welds small diameter cylinders. trode. When more than one electrode necessary complete the joint the resultant crater may found objec- tionable and also the time saved may small, compared with doing the same job with hand welding. Stick Feed Head Applications the stick feeding device, Fig. which may added standard bare wire automatic are welding head have been limited principally circular welds shell cases and other small cylinders where high-quality, flat-contour welds are required. This equipment has the ad- vantage making possible the use any diameter type welding electrode. usually possible choose the electrode for ticular job that stub end kept the minimum. The stick feeding device at- tachment for bare heavily coated type automatic are which allows the use single sticks standard manual welding The electrode inserted clamp the stick feeding attachment and fed into the are under controlled conditions until the electrode con- sumed. this point the clamping returns automatically its starting point where ready for the insertion new stick electrode. arrangement High-quality welds moderately heavy base material frequently are most economically made through the use automatic are welding head that uses heavily coated electrode coils, Fig. One form this equipment uses electrode having woven, flux-impregnated coating which quite flexible and which will adhere the core wire the elec- trode unrolled from reel and fed into the Current introduced into the electrode milling nar- row slot through the coating passes through the head and allow- ~ = par- will at- oated head, sticks ‘lamp and rolled con- iping urns eady ately are the head this ating will elec- fed nar- llow- ing set current-carrying fingers ride the slot against the core wire. arrangement such this used both straight and circular seams and possible equip the head with oscillating attachment will deposit wide layers. For making butt fillet welds sections in. thick and above, the submerged melt process will many cases prove most economical be- cause joints may made single relatively few passes high weld- ing speeds using currents from 600 800 amp. and even 2000 amp. more plate in. thickness and above. For certain hard-to-weld metals none the above automatic welding processes satisfactory. Frequently, the automatic atomic hydrogen process the only automatic welding process which may applied, Fig. For welding aluminum, steels and certain special alloys, par- ticularly thin sections such in. where the weld requirements call for extreme duc- ABOVE 3—Automatic welding head and rotating fixture for making circumfer- ential fillet welds wheels medium tanks. milled the heavily coated electrode wire establish elec- trical contact just before the wire feeds into the arc. tility for the weld metal have practically the same composition and physical properties the base metal, automatic atomic hydrogen welding the sole choice, excepting hand welding. Regardless which automatic welding process has been chosen for particular job, relatively easy visualize the savings which may expected through its use. The average hand welding job will have cost analysis approximately fol- lows: Factor Per Cent welding job the principal item, may expected that through the reduction this item the principal savings may made with the auto- process. Time studies the average arc welding operator show that the actual time that weld- ing will somewhere the range per cent, exceeding the upper figure only extremely rare eases. has also been found that his duty factor and therefore his pro- duction drop off sharply towards the the day that his average may much less than that indicated time studies relatively short periods. The reduction production toward the end the day often caused operator fatigue because the strain holding accurate arc length and traversing seam, hour after hour, production line weld- ing. Because strict code require- ments and rigid inspection, also frequently necessary re-weld some the joints. has been found that the number re-welds and rejects increases rapidly toward the end the shift. Higher Duty Factor With automatic are welding equip- ment, possible maintain the are per cent the total time. Since the controls the auto- matic welding equipment are present for particular jobs and the operator under physical strain, this high production rate may maintained throughout the day and the number rejects—considerably fewer than 4—General Electric multiple-arc atomic-hydrogen welding equipment used for welding tubing for automotive axle housings the plant the Clark Equipment Co. Flat strips medium carbon steel are formed into tubing and passed propelling and squeezing rolls under series atomic hydrogen arcs. Finished tubing very strong and ductile, the weld being subjected severe swedging, expanding and form- ing subsequent manufacturing operations. Control operations grouped compact pushbutton panel just above the knees. Electrical equipment for supplying power the arcs and electronic control for the electrode feeding motors the welding head are housed cubicles behind operator. THE IRON AGE, July 29, 1943—43 with hand welding—will show in- toward the end the day. Perhaps the greatest recommenda- tion for automatic welding the fact that operators can trained handle this equipment tremely short time. They need noi skilled welders for that matter able weld: all. Such opera- tors can frequently hired more easily than skilled welding operators. The same operator may able more than one automatic welding equipment one time the machines are conveniently While one machine being loaded and the are started, the other machine welding. Limit switches may employed stop the welding head automatically and return the starting position for the next weld. When the welding operator tends two welding heads, the welding labor cost per unit reduced very small fraction the cost for hand welding the same joint. Reduction the number rejected pieces and those requiring patching will result still further reduction unit cost. hand welding jobs, electrode stub end losses often run per cent more the total amount electrode purchased and this waste principally responsible for the rela- tively high cost electrodes. When the automatic welding process uses coiled electrodes, stub end loss cut practically zero, further sub- stantial savings favor auto- matic welding. Current Used Since the welding current auto- 44—THE IRON AGE, July 29, 1943 LEFT weld, and macrosection, made with automatic heav- ily coated arc welding head using diameter coiled electrode operating with 510 amp. a.c. travel speed in. per min. RIGHT 1000-amp., 440/550 volt a.c. transformer type arc welder, most fre- quently used power source for high quality automatic arc welding equipment. matic welding processes introduced into the electrode very near often possible use welding currents per cent higher than possible with hand welding, with- out overheating the welding electrode, damaging the coating reducing weld quality. This, course, results increased electrode melting rate (see Fig. which turn results higher welding speeds than with hand welding. These higher welding currents result greater power con- sumption the d.c. set a.c trans- former-type welder, Fig. used power source. This, however, does not mean that the per cent power cost the above tabulation will increased, still takes the same number kilowatt-hours melt pound electrode whether hand automatic welding used. changing existing welding job from hand welding the auto- matic process, careful attention should paid the source welding power since this power will used considerably higher duty factor and higher welding currents. The following simple formula for calculating the size single-oper- ator type welder when the weld- ing current and duty factor are known. Vduty factor welding current. The duty factor (expressed 1.25 decimal: per cent 0.80) usually taken the number minutes out each that the are actually going. extremely long seams multi-pass circular seams where the time required make single joint exceeds min., the duty factor should considered The next large size standard rating welding set indicated the formula should chosen. For in- stance, should the rating calcu- lated 280 amp., obviously 300- amp. set should chosen. selecting the type are welder for use with automatic welding equipment, a.c. offers many ad- vantages over d.c that present used almost exclusively wherever automatic are welding applied with heavily coated electrodes with the submerged melt process. Among the principal advantages a.c. welders are: (a) strength and faster welding due the absence troublesome magnetic disturbances the arc; (b) Savings maintenance since a.c. welder the transformer type operates static equipment; (c) and consider- nt. are long seams ake duty 1.00. the ad- rever with the the arc iform vings elder sider- able saving power because much higher efficiency. Fixed charges will, course, considerably increased when job changed from hand welding a