The Iron Age 1943-08-26: Vol 152 Iss 9

important remember that nobody “e ever Fortress Liberator ora Lightening. They are built from endless thousands parts, many them turned out New Britains. just vital that aircraft AUG 1943 factories get ignition terminals, That knowledge inspires who build New Britains, never let down. pass you who use them the hope that will remind you, too, the urgency your job. NEW BRITAIN-GRIDLEY MACHINE DIVISION THE NEW BRITAIN MACHINE CO. NEW BRITAIN, UGUST 26, 1943 Engin. 3 4 as por , “Not one penny for The operating executives some America’s largest corporations have been reporting the performance their Cleveland Worm Gear Speed Reducers—some installed early 1920. the vital subject repairs, them have made these amazing statements:— than years with not nickel’s worth “Clevelands installed 1925—never have needed years—300 days year—still running like new”. “Every hour the year; attention except check “Over years without inspection. Clevelands give satisfaction every “Since 1929 our conveyors. replacements. selected Clevelands account their good record our other “Over years and parts failure. Four our plants have bought more than 200 your “Our first Clevelands installed 1924, still going strong; vital our continuous Designed, built and installed years ago, thou- sands Cleveland Drives are helping carry today’s burden war production with never hour shutdown time—never cent for parts replacement. Clevelands your new equipment will serve you just faithfully through all the critical years come. Write into your Conversion spec- ifications—send for the Cleveland Represen- tative now. THE CLEVELAND WORM GEAR COMPANY 3252 East 80th Street Cleveland Ohio Affiliate: The Farval Corporation, Centralized Systems Lubrication. Canada: PEACOCK BROTHERS LIMITED SPEED REDUCERS THE IRON AGE, published every Thursday the CHILTON CO. Entered second class matter November 1932, the Post Office Philadelphia act March 1879. yearly North America and South America, Foreign $15. Vol. 152, No. = lish Nor Poss Sing F President and Editor BAUR Vice-President General Manager Editorial and Advertising Offices East 42nd St., New York Y., Johnson, Market Research Baur, Typography and Layout. Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. Pittsburgh Guardian 428 Park Philadelphia Chicago Chilton Bidg. 1134 Otis Bidg. PEIRCE LEWIS WARREN Detroit Hartford Conn. RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY (Incorporated) Executive Offices Chestnut and Sts., Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH GEORGE GRIFFITHS EVERIT TERHUNE VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE THOMAS KANE Vice-President Vice-President Member, Audit Bureau Circulations Member, Associated Business Papers the Industrial Arts Index. Pub every Thursday. Subscription Price America, South America and Possessions, $8: Foreign, year. y Single Copy, cents. Annual Number, ° ° ° Vol. 152, No. Week The Editorial You Will Need After the War Technical Articles Mass Production the Carbine Sheet Metal Work Puget Sound Navy Yard Welding Light Metals Ingenuity Makes for Lack Special Tools Conveyor Aids Parts Inspection Features News Front Assembly Line Washington Fatigue Cracks Dear Editor News and Markets Expansion Program Post-War Fears 48-Hr. Coal Week Hit Costs Personals and Obituaries Machine Tool News Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Steel and Warehouse Prices Stainless Steel, Tool Steel Prices Semi-Finished Iron and Steel Prices Pig Iron Prices .......... Ore and Coke Prices Ferroalloy Prices Index Advertisers ‘ August 26, 1943 q Office ¥ Ryerson Stock for Immediate Shipment Reg Pictured above are steel stocks one the ten Ryerson plants. Ready for immediate shipment are thousands kinds, shapes, and sizes steel fill the requirements war industries and the manufacturers essen- tial civilian goods. Rush orders, equipment breakdowns well the normal demand for small lots steel make highly important have source ready with the right steel meet all emergencies. The ten Ryerson Steel-Service plants are geared for just this operation. The steel carried Ryerson stock makes practical for manufacturers reduce high inventories—eliminate idle steel and make every ton work for victory. nearest Ryerson plant when you need steel. JOSEPH RYERSON SON, INC. Plants at: Chicago, Milwaukee, St. Louis, Detroit, Cincinnati, Cleveland, Buffalo, Boston, Philadelphia, Jersey City IRON ESTABLISHED 1855 VAN DEVENTER President and Editor BAUR Vice-President and General Manager DIX Monager, Reader Service ° ° ° Managing Editor....... LIPPERT News, Markets Editor...D. JAMES Technical Editor......... OLIVER ° ° ° Associate Editors MacDONALD BARMASEL Editorial Assistants SCHIEN WILLIAMS BUTTERS Regional News and Technical Editors CAMPBELL Pittsburgh 428 Park PHAIR Chicago 1134 Otis Washington Press BROWNE Washington National Press LLOYD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle You Will Need After the War New Philosophy Public Debt,” Harold Moulton, the Brookings Institute, book that you will find worth reading. contrasts the two schools thought regarding national finances, the one stating you must work for prosperity and the other proposing you can spend your way into it. Those who have been brought the mechanical industries are inclined take the conservative viewpoint. Our training mathe- matical one; believe that two and two make four, and know that given expenditure time and energy necessary produce any commodity. have seen veritable miracles performed production, but have never known any miracle men. The miracles always had per- formers back them who were hard workers and headworkers and who “knew their onions.” The “tax and spend” boys not believe balancing the national budget. They not believe reducing the national debt even holding any given level. Some them believe that can safely maintain debt large two trillion dollars; plain language, 2000 billion. These same gentlemen who talk glibly and convincingly about lift- ing ourselves our bootstraps would certainly not advocate inflation the printing press route. They would not advocate unlimited outpouring and dollar bills. But effect they advocate ex- actly that, except that the legal illegal tender involved instead being greenbacks bonds. You can arrive inflation just quickly and surely and perhaps more printing bonds with denominations $10,000, $1000 $500 printing greenbacks and $10 values. The specious reasoning back this distinction without difference the statement that since national debt merely owed ourselves are auto- matically “square” all times, regardless the paper figures. Inflation, according the dictionary, means blow with gas air, presumably hot air. There has been plenty that; fact, more than enough. Every worthwhile manager industry has constant fight with infla- tion his hands. His job that deflating costs. knows that you have put take out. may not economist (perhaps can thankful for that), but has instinctive realization the fact that there has never yet been invented satisfactory substitute for economy. are going need plenty that after the war. Nine-tenths the money being spent this country today non-productive the sense that its purpose destroy, not create. going each and every one us, the days come, turn things around again and get the cart behind the horse, where belongs. Otherwise our tombstone may bear the epitaph: “He lended, spended and now he’s ended!” — | ° ° ° q i : teal il | \ There are many types employment open women machine operation, welding, stenography, laboratory work, etc. The need great that woman should able find exactly the type work for which she best suited. Perhaps Joan Could Help, Too! Have you stopped consider there place for your sister, your daughter yes, even your wife the great effort the metal working industry making help win this war? Through your everyday conversation the women your family realize the need for more production. They know about the shortage workers. They know that patriotic work, but because their place has been the home, many them are timid about going work office factory. You, worker America’s great metal industry, can dispel that timidity them about the many kinds jobs open women. Let them know that they are safe the factory the home; that modern Ameri- can factories are clean; and that factory associa- tions are interesting. Talk Joan, Helen, Barbara this evening. years come they will proud the work they did help keep America’s homes safe and free. Check your local help wanted ads for specific needs your area, ask the local Em- ployment Service. INLAND STEEL COMPANY Dearborn St. Milwaukee Detroit St. Paul 40—THE IRON AGE, August 26, 1943 St. Louis Chicago Illinois Kansas City Cincinnati New York will sheet will stee. 30, atta ever Van per tons conc 1920, fire will the first foreign electrolytic tinning News AUG. 26, 1943 Ore prices, long frozen vertically (average $4.24 ton) and with $4.45 ceiling, will soon unfrozen and the ceiling lifted near $4.60 OPA. Operators wanted $4.75 top; particularly welcome, however, will thawing escalator clauses contracts. Current ore price relatively low: 1918 was $5.36; 1919, $5.48; 1920, $6.36. Flying Fortresses, their daylight raids Germany, travel geometrically perfect formations (horizontal vertical V). Over comparatively small objective, bombs down one devastating cascade. The objective usually vanishes. German fighters attack Fortress formations from the front, preferring the hazard the two Fortress nose guns the heavier turret fire the beam astern. the German snap-shoots (the aircraft approach each other 550 m.p.h.) rolls over defensively present only armored belly the Fortress's bullets close quarters. Nose turrets for both American and British bombers are the way. is, bombers are being weighted down with many guns and armor, and require much ammunition constantly force off fighters, that raids beyond Berlin will have await the arrival the new Tubular construction aircraft engine mounts has given way solid drawn sheet design, said permit change engines per cent the time required the tubular mount. Britain's Richard Thomas Co., Ltd., has just signed contract for delivery American wide continuous electrolytic tinning unit. Equipment will shipped about months, and crews will sent here pick operational know-how. This The Quebec conference has already resulted great flurry all Government procurement agencies, the orders being get maximum production all equipment needed for amphibious warfare, from spools thread battleships. And: The war production program, far from remaining static rising slightly, will likely soon stepped considerably, including quite extensive new plant building. Aircraft output will lifted considerably. More aircraft requires more aluminum extrusions, and three new may soon the South, the West and the East. Over month ago News OPA may set Kaiser's ingot price high $40. Announcement has just been made that the base will $43, $12 above that for other steel companies; even so, this price may not cover Kaiser's high costs. Allied strategic bombing the German Ruhr opposed fully 1000 fighters and 30,000 guns. German light flak particularly deadly, virtually ruling out low-level attacks. The recent tow Waco glider was hailed phenomenal. 1930 Captain Frank Hawks landed his enclosed cabin glider, the Eaglet, Cortland Park, New York, after being towed from San Diego. British steel output currently rate equivalent about 1,000,000 tons per year above the 1942 level. Last year one ton scrap was imported for every 722 tons steel made. far this year, scrap has been imported, other than the concealed scrap going there from the semi-finished steel. get net increase 12,000 workers, West Coast aircraft plants hired more than 150,000 new employees the first six months 1943. Although high explosives (block busters, etc.) get all the newspaper headlines the German raids, photographs show that far the bulk the damage done fires set incendiaries. Italy, however, the damage high explosives pro- much greater than Germany. Aluminum and magnesium casting producers predict that centrifugal casting will greatly improve the light metals' competitive position after the war greatly the yield such metals. Experiments suggest that yields should Cally high One foundry centrifugally casting feels confident that last has found the answer the oxidation problem. | 4 q q 4 { tion No. Operation Wash and demagnatize Rough gang bottom bar. Rough gang mill bottom bar Finish gang mill bottom and square Drill spring Drill hole... Counterbore hole. Burr Ream bolt hole Inspect Rough gang mill top Finish gang mill top Gang mill sides recoil base Gang mill bottom and back recoil base. Gang mill top recoil mill and slot. Gang mill step right Spot and bottom drill Mill side groove, right side Profile front end slide Mill undercut slide Wash Rough drill magazine opening hole magazine opening End mill magazine seam clearance Inspect Finish mill hammer opening End mill step hammer opening End mill bolt Inspect End mill firing Mill cartridge ramp. Mill bolt guide Inspect Drill and ream 0.180 in. Form Inspect Cut-off square corners Form mill radius. End mill bolt cam opening End mill chamber. End mill radius and angle Inspect End mill assembly Finish mill chamber locking slot. End mill top bolt End mill step front end... Stamp TABLE Manufacturing Steps for Receiver Cal. 0.30, Carbine Machine Used and Number Required No. 213 Campbell abrasive saw 30-in. Hand operation No. 2-24 Cincinnati plain miller No. 2-24 Cincinnati plain miller 2-24 Cincinnati plain miller Krueger Special 8-spindle drill press Krueger Special 8-spindle drill press Krueger multiple head, semi-automatics Hand operation Krueger Special drill press No. 2-24 Cincinnati plain miller. No. 2-24 Cincinnati plain No. 1-18 Cincinnati plain No. 1-8 Kent-Owen plain miller No. 1-18 Kent-Owen plain miller. No. 1-6 Multi-Miller No. 1-18 Cincinnati plain miller Allen drill press, No. 0-8 Cincinnati rise and fall miller No. Pratt Whitney profiler No. 0-8 Cincinnati vertical miller No. Allen, drill press No. 12B Pratt Whitney, 2-spindle profiler Morey profiler No. Allen drill No. 12B Pratt Whitney, profiler No. 1-5-2 Multi-Miller No. 1-5-2 Multi-Miller No. 1-5-2 Multi-Miller No. 1-5-2 Multi-Miller No. 1-5-2 Multi-Miller Thompson Hand operation with fixture Thompson profiler No. 1-5-2 Multi-Miller No. 0-8 Cincinnati vertical miller No. Allen drill press, 5-spindle Kent-Owen hand miller No. 1-18 Cincinnati plain miller No. 0-8 Cincinnati plain miller No. 0-8 Cincinnati No. 0-8 Cincinnati plain miller No. 1-60 Multi-Miller No. 1-60 Multi-Miller No. 1-60 Multi-Miller No. 1-8 Kent-Owen miller No. 1-5-2 Multi-Miller Allen-1-spindle drill press Pratt Whitney spline No. 1-6 Multi-Miller Pratt Whitney Pratt Whitney shaver No. 0-8 Cincinnati vertical mill No. 1-5-2 Multi-Miller. No. 1-5-2 Multi-Miller Hand operation with fixture and die Bench Hand filing No. 175 Schmidt marking machine No. Schmidt marking machine No. 175 Schmidt marking machine Bakewell 1-spindle lead screw tapping Hand washing Lindberg Cyclone electric furnace Countersink front end spring Stamp: “U. Carbine, Cal. Finish tap thread bolt Inspect Heat treat. Inspect Sandblast Parkerize Final inspection and delivery assembly machine tools 42—THE IRON AGE, August 26, 1943 132 (2) (2) (2) (2) (2) (2) (2) (2) (2) (3) (2) (2) (2) (2) (3) (2) (5) (1) (2) (2) (6) (3) (2) (1) (2) (2) (3) (3) (2) (1) (1) (2) (2) (2) (2) (2) (1) (2) (2) (2) (2) (4) (3) (2) (2) (2) (3) (1) (6) (2) (1) (2) (1) (2) (2) (2) (2) (1) (1) (1) (1) (1) ° ° THOMAS LLOYD Cleveland Editor, THE IRON AGE ITH the burning recollection that fellow workers and bands, and sons the people Port Clinton, Ohio, were among those lost the Bataan Peninsula when the Japs overcame those American troops that held out the last give other American forces the Pacific more time, workers Standard Products Co. are personally aiming see that American forces any will never run short again —at least caliber 0.30, M-1 car- bines. From population 4350 1940, this town has grown size un- til today there are some 7300 persons living there. But the fall Bataan will long remain memory these folks, since about per cent the entire population was lost nihilated one single stroke. This group men lost Bataan made Company “C” Gen. famous 192nd Tank Battalion. Standard Products Co. today the manufacturer the M-1 carbine rapidly approaching peak produc- tion. The original contract, signed September, 1942, called for more than quarter million guns, and from Sep- tember January, 1943, tooling operations were under way. these five short months, approval ma- chine tool lists and procurement the tools took place. 4:00 New Year’s day the first five guns were completed, made mostly room equipment. Since that time, pro- duction has gained steadily and early September this year, the maximum production rate expected reached. Standard Products Co. one eight companies that were prime contractors the original con- tract award. When the original con- tracts were let, Standard had one the three largest, but since that time other larger manufacturers have had their contracts upped considerably. only setti products, make. the parts, the recei assembles The the and request weapon arm holds and the exhaust mechanis Manufac Wine lron Age The Spring and pick bar The the finis Abc remov fore fina finish The | ° ° ° ura; | finic While forgir Blave the 4 | = Manuf ac and lost the cific any rain car- un- sons aan the an- ur’s day bine duc- han hese ma- runs tool pro- the only con- con- had before Production Set-Up setting into gun pro- Standard Products Co., which the war and rubber and plastic products, lined its sub-contractors handle parts that could not make. Now, sub-contractors han- the production all component parts, while Standard manufactures the receiver, the bolt, the trigger housing, and the operating slide, and and tests the finished guns. The M-1 carbine development the Winchester Repeating and evolved from the Army’s replace the 0.45 Colt Automatic the 0.45 revolver side- issued officers. The gun which wit similar that the Garand and the action also similar, using gases actuate the firing and eject the empty shell. Manufacture the gun produced Winchester was described The Age, April 1943, page 47. Receiver Production The receiver, Fig. machined from Armory grade gun open hearth steel, annealed and pickled. The steel purchased bar stock form and cut length. The weight the bar blank about but after completion the ma- thining operation shown Table finished receiver weighs only 9.5 About per cent the steel Sremoved. After machining and be- final inspection, the part heat and tempered. Parkerized protects the metal from cor- The trigger housing, Fig. ob- the form rough forg- weighing about oz., and open hearth forging quality After complete machining, the housing weighs only 6.5 oz. this part now purchased ‘forging, plans are under way the rough part stamped the Ohio Mfg. Co., Cleveland, and equipment now being set Talon, Inc., Meadville, Pa., manufacturers the Talon zipper Total war came home roost Port Clinton, Ohio, when 140 its sons were lost Bataan. Now, those home this sleepy little resort town are working with vengeance turning out the cali- ber 0.30, carbine Standard Products Co. will Table II. side view the re- ceiver, the main body the carbine. view the trig- ger housing the carbine. 3—Bolt and operating slide the carbine. use stampings instead forg- ings will eliminate nearly per cent the machining operations shown Like the receiver, the stampings. The housing also given Parkerized finish. The rough bolt the carbine Fig. also forged, but double. That is, each forging yields two bolts. The BARREL HOLE CARTRIDGE MACAZINE OPENING REAR SIGHT BASE OPERATING SPRING TUBE RECESS OPERATING SLIDE CATCH HOLE LOCKING SLOT RIGHT SIDE HAMMER HAMMER SLOT SPRING SEAT TRIGGER SLOT RETAINING LUG OPENING RETAINING LUGS ¥ MAGAZINE CATCH SLOT PIN HOLE LEFT PLUNGER HOLE CAMING LUG RECEIVER HELIX GROOVE 4 HOUSING RIBS OPERATING SLIDEWAY RECESS PLATE | THE IRON AGE, August 26, 1943—43 TABLE Manufacturing Steps for Trigger Housing Cal. 0.30, M-i, Carbine Operation Machine Used and No. Required Grind sides forging Gang mill top and straddle mill Gang mill Form mill top complete Burr. Inspect Rough and finish end mill maga- zine opening End mill right side trigger End mill left side trigger hole. End mill pad, left side trigger End mill front corner trigger guard End mill pad, right side guard...... Inspect and ream cross holes and ream Inspect mill radius and bevel front Rough and straddle mill Mill slot and straddle mili Counterbore for springseat Broach ends magazine opening. End mill right side Inspect Finish profile T-slot Profile trigger End mill left side. End mill radius back end Profile right and left Profile mill Burr and finish Inspect | Stamp mill Rough out trigger Shave out trigger opening Shave out trigger opening, Wash Washing and rinse Sand blast Parkerize Final inspection and delivery assembly. Total machining operations Total machine tools required Pratt Whitney shaver 30-in. Blanchard No. 2-24 Cincinnati plain (2) No. 2-24 Cincinnati plain (2) No. 2-24 Cincinnati plain (2) Hand operation No. 12B Pratt Whitney 2-spindle pro- No. 1-6 Multi-Miller............ (2) Thompson No. 1-M Kent-Owen hand No. 1-M Kent-Owen hand (1) Hand operation Allen 2-spindle drill press with 5-spindle No. Allen, 6-spindle drill (2) No. Allen, 4-spindle drill press Hand operation No. 0-8 Cincinnati plain (2) No. Allen 1-spindle drill No. Pointe broach, (1) V-50 American broach, (1) Kent-Owen hand miller (1) No. 12B Pratt Whitney 2-spindle profiler No. 12B Pratt Whitney 2-spindle No. 1-18 Cincinnati plain No. 1-18 Cincinnati plain No. 1-M Kent-Owen hand (2) No. 12B Pratt profiler, No. 12B Pratt Whitney profiler, No. 12B Pratt Whitney profiler, No. 1-M Kent-Owen hand No. 12-B Pratt Whitney profiler, 2-spindle Pratt Whitney shaver Hand burring and filing Bench operation with fixture and die Alkaline wash, dip method forging weight 5.5 oz., and gun quality, open hearth forging ste used. The machining operation finishing the bolt are shown Table III. After machining, the heat treated. Being moving and subject more wear and sion than other parts, the bolt the hardest part the gun. Afte heat treating, the bolt given Dp. lite finish, which oxide phos phate blackening process. Operating Slide Production The operating slide, shown with form forging weighing over 1.25 lb. The steel used ing the forging ope hearth forging grade. Machining Table IV, which reduce the weight the part 7.75 oz. finished applied the operating slide after heat treatment, receiver and trigger housing. When setting for the ture this gun, Standard Co. found necessary re-tool its Port Clinton tically every piece equipment use the machining these parts new. Because the difficulty ing carbide cutters, the standardized high speed steel. centralized tool crib tools was set up. This was foundt Fic. 4—The use mechanical fixtures machining gun parts Standard Co., Port Clinton, Ohio, quite extensive Here, the fixture driven the shaft from pract type able, anc running operators for establ arra has been well. help the gang tool mak general bide tool pend alt ability that pro considera bide the core spring the use reduce machines Also, removal ing has slides ina abrasive three the motor thown are | Opera- 44—THE IRON AGE, August 26, 1943 practical mainly because the type help that was available. TABLE machinists were not obtain- and order keep machines Manufacturing Steps for Bolt Cal. 0.30, Carbine handling tools that unskilled Opera- would not responsible tion No. Operation Machine Used and No. Required established. With the few skilled Kent-Owen hand miller.............. (1) crib arrangement was established and Rough turn and Lipe 9-in. production lathe............ (1) been found work out extremely Rough turn, face............. Lipe 9-in. production lathe............ (1) well. This tool crib has also been Inspect tooling machines. Many Drillandream............... No. 601DD Oster Rapiduction (3) move toward the use car- Pilot center No. Allen, drill (1) tools expected take place Inspect shortly, the extent which will de- turn and Lipe 9-in. production lathe............ that production can speeded No. 0-8 Cincinnati plain (2) tipped cutters. For example, No. 0-8 Cincinnati rise and fall miller. (1) granite gravel, steel shot, and End mill left side, front Whitney 2-spindle, machines are order. These Cut and out, No. 12B Pratt Whitney 2-spindle End mill No. 1-8 Kent-Owen plain (2) End mill radius, No. 1-14V Kent-Owen plain End mill No. 21B Pratt Whitney 2-spindle Buff and finish small Hand operation with fixture and die Inspect Wash and rinse Heat treat Rockwell test Hand operation, fixture and die Alkaline wash Lindberg Cyclone furnaces, batch charge wire baskets Bath dip coating, batch charge wire baskets Final inspection and delivery assembly Total machine tools required......... when the new tumbling units are in- stalled. difficulty the beginning, this diffi- culty again being traceable the scarcity skilled help. engineer- ing department was set especially for tool and fixture design and this work got under way quickly and efficiently possible. For this work, like for other jobs that required men Jig Design Problems Tool and jig design for the huge quantity machine tools purchased and for the multitude various op- erations performed presented another THE IRON AGE, August 26, 1943—45 { 4 = 5—A cam recess helix groove had cut the operating slide ical fixture had designed. With the aid the manufacturer the ma- chine, Multi-Miller, the fixture shown above, was developed, enabling the use unskilled help handling the machine. high skill, the country was pretty well combed. Tool and fixture de- signers, gun smiths, engineers. tool foremen and other men similar skilled capacities were hired from many points. Michigan, Penn- sylvania, Ohio, New York, Connecti- eut, Illinois and many other states are represented the mobilization skilled help run this Ohio small arms plant. Those fixtures the engineering de- partment was unable develop, the tool manufacturers For example, rotating fixture used with the help the machine tool builder. This fixture, powered off the motor the tool, rotates the receiver the carbine such manner that milling cutter brought bear the hood end and mills the part perfect arc the outside face, while another similar fixture was de- signed for milling similarly shaped shoulder the underside the re- ceiver hood. The fixture for milling the shoulder the inside the hood, shown Fig. Another fixture that re- 46—THE IRON AGE, August 26, 1943 Opera- age quired outside help designing that shown Fig. Here the set for the milling the recess helix groove the ming lug the operating slide carbine. Like the other fixtures this powered off the brings the cam lug bear the milling cutter such way cuts shaped groove about in. wide and about the same for about in. along the TABLE for Slide Cal. 0.30, Carbine Operation Machine Used and No. Required Rough gang mill right side End mill locating Finish gang mill top, front Finish gang mill bottom Mill contour fingergrip Gang mill right Gang mill left side Gang mill left finish Burr Burr Inspect Form mill left form End mill top and left Inspect Rough form end mill, cam Form end mill. Form mill.......... Form end End mill Inspect Mill bevel front end Form mill End mill end right End mill end housing. Drill and burr hole......... Rough end mill cylinder wall Finish profile cylinder wall Cam Mill final finish Stamping Inspect Mill both sides Cut out front left rib Finish filing Wash Inspect Wash and rinse Heat treat Inspect Sand blast Parkerize Final inspection and delivery assembly Total machining operations............ Total machine tools required........... No. 2-24 Cincinnati plain No. 12B Pratt Whitney, 2-spindle No. 2-24 Cincinnati plain No. Brown Sharpe plain No. 2-24 Cincinnati plain No. 2-24 Cincinnati plain No. 2-24 Cincinnati plain Hand operation No. 2-24 Cincinnati plain No. Brown Sharpe plain No. 1-M Kent-Owen hand Hand operation No. 1-M Kent-Owen hand No. 1-M Kent-Owen hand No. 1-M Kent-Owen hand No. 1-8 Kent-Owen plain No. 12B Pratt Whitney, Hand operation No. 12B Pratt Whitney, 2-spindle Hand operation No. Brown Sharpe plain No. 1-60 Multi-Miller No. 1-8 Kent-Owen plain No. 0-8 Cincinnati vertical No. Allen drill press, No. 0-8 Cincinnati vertical No. 12B Pratt Whitney, 2-spindle No. 1-M Kent-Owen hand Hand operation Hand operation with fixture and die No. 1-5-2 Multi-Miller.......... Bench operation with arbor press shaver Hand operation Alkaline wash, batch charge Lindberg Cyclone furnace lug. ling assemb are indi leaves subject diamet this gun pre the box lever Foll gun ing azine lowed compa men. obtain Erik the all ove expert made has mally chines this bar No. plate trimn the The troug tural laid hose pipes bar. the fixed maki and 6 8 } 7 | | dle ess Another example special tool- ling shown Fig. make certain that all carbines assembled Standard Products Co. are 100 per cent perfect, each gun individually “proofed” before leaves the plant. First, the gun subjected per cent “fire-over- load.” slightly larger diameter than standard 0.30 cal. am- munition fired from the gun, and this overload sufficient blow the gun apart construction faulty. prevent mishaps such case, the gun encased armor-plate box and the trigger stripped lever through the side the box. Following the overload firing, the gun function-fired, the magazine be- ing loaded and fired repeatedly quickly possible. The 15-shot mag- azine loaded and fired repeatedly quickly possible. This test fol- company’s own range expert rifle- men. Here again example obtaining skill from remote parts. Erik Johnson, many times winner the small and large bore rifle meets all over the world, one the many expert riflemen who help target these carbines. Thorough target tests are made and any adjustments necessary 1G. 6—This Krue- ger special 8-spin- dle drilling machine, using special gun barrel drills and reamers, core drills the spring hole and the bolt hole the ing the machine enables the use quickly trained help. perfect the sights the gun are made these riflemen. Every gun that leaves the plant’s range with the weapon, able hold its own with most target rifles. Cantilever Bar Increases Radiagraph SHOP built device for multiply- ing the productive output portable Radiagraph cutting machine has been put use New England shipyard, accomplishing the work nor- mally produced two more ma- chines. shown the photograph this attachment consists 10-ft. bar balanced crosswise Airco No. Radiograph, with the ends sup- ported cantilever fashion buckled rods welded the apex section. This bar carries four torches adjustable positions for trimming parallel edges simultaneous- two plates, one each side the machine tracks. The 40-ft. track laid the trough several sections struc- tural channel welded end-to-end, pro- viding protection while plate being laid out. Cumbersome lengths gas hose are eliminated the use gas pipes mounted parallel the torch bar. Four round mounting pads are the bar that the torches can any position along the bar, making fine adjustments the rack and supporting each torch. While this device limited appli- cation compared the large shape- cutting machines whose territory trespasses upon, very service- able substitute. contrivance for plate squaring, powered standard portable Radiagraph cutting machine. THE IRON AGE, August 26, 1943—47 fixtuy 4 Sheet Metal = ; 13—Formed “half elbow before trimming. This method pressing ventilation elbows was developed and the sheet metal shop the Puget Sound Navy Yard. Note the double-action forming dies and the draw ring mounted 450-ton H-P-M hydropress. IG. 14—The simultaneous trimming outside and inside flanged edges half nut" for watertight ventilation elbows, using revolving motor-driven table and two acetylene torches. This operation immediately precedes arc welding. 48—THE IRON AGE, August 26, 1943 H & the first part the article the extreme versatility the drop hammer was pointed out, and was indicated that for several sheet metal jobs, the same dies could used either the drop hammer the hydropress. This 425-ton H-P-¥ hydropress equipped with two upper slides and one hydraulic cushion the bed and adaptable for all classes sheet metal forming from single triple-action work. Actually very little triple-action work done, but the lower pad comes handy for verted double-action drawing opera- tions. 10-in. rubber pad available for single-action hydropress forming with rubber according current practice the aircraft industry. However, the limited tonnage available makes such forming possible only small Mostly the 2-in. rubber pad illustrated use the drop hammer Fig. the first part the article used for similar blanking operations the hydropress when the drop mer otherwise employed. Watertight Elbows The manufacture water-tight elbows typical double-action job done the hydropress. The first step the operation the formation “doughnut” halves cast dies shown Fig. 13. The black plate 0.109 0.125 in. ness, and after drawing, the halves are trimmed with lene torch, Fig. 14, and are welded gether around the flanges. Elbow sectors any angle, such 60, 120 deg., may then cut out doughnuts band saw, Fig. These elbows are then welded inté the piping system, using flange com nections made the drop hammer. One the biggest production done the hydropress the facture metal joiner doors. doors are made two formed 0.037 in. black sheet spot welded together make door 26% in. and several different heights. door halves are formed action die which made with able end sections accommodate the different heights mentioned. The are The new sheet big weight ime, besi struc Fig. nounted hat bach end. with plat the Bhe two for doors double ressure | | + Puget Sound Navy Yard for with the such rated ‘ig. used -tight first steel rial thick jobs halves velded wide The the are positioned dowels and bolted the several positions door Formerly these doors were shears and press brakes. The new design reduces the number them small parts, plus the big panels), saves considerably weight and enables complete door made one-third the former ime, besides giving much stronger structurally. Fig. shows the adjustable door die that overhangs the bed in. end. This die made welded with the lower portion made plate supported H-sections the upper platen welded chan- two cross pieces the die are lengthwise along the rails doors varying height. This double action die with holddown pressure pad, also adjustable length- ABOVE and semi-finished watertight ventilation elbow These doughnuts are cut any desired angle. Sample cut segment shown top left-hand pile. The two halves doughnuts are this case arc welded together. ° LEFT double-action draw die for door panels mounted the trates the press opera- tion, the ram and hold- down ring having just been retracted. This fully illus- trates the welded construc- tion the punch, hold- down ring and bed plate extensions and shows the wrinkle-free complished accurate die-making. FRANK OLIVER Technical Editor, Ace ° ° the second and concluding part this article, typical work done the hydropress illustrated and other types sheet metal forming are described. This shop well equipped handle all kinds fabrication resistance welding. The material for this article was placed the disposal Hibbard, master sheet metal worker, and Albert Taylor, foreman the sheet metal shop. All illustrations are from official Navy photographs. wise, and the fact that the ram pres- sure can equalized the four cor- ners the moving platen assures the proper pressure the sheet all four sides when the punch descends. Making Galley Tubs Another interesting job done the hydropress the manufacture gal- ley tubs, which are merely large cook- ing pots holding about gal. Former- these tubs were made stainless steel. Now they are made sections from steel plate which given corrosion resistant finish baked two coats. The main body the tub made fiat sheet and developed section cut circular shear and rolled and resistance manner fusing filler wire into THE IRON AGE, August 26, 1943—49 ° the heet the P-M pper little curling completed the lower dip half the second stroke. ment. the die halves are made the clas nickel cast steel, this case flame hardened for wear resistance. The bottom die may also employed the Cecostamp. Ther turret butt seam, shown Fig. 18. The tub trimmed both top and bottom Niagara circular shear carrying and 20. Note that the work sup- ported horizontally pair ball bearings, allowing the piece re- volved freely the rotation the shear blades. This operation corrects any errors shearing the flat, de- veloped section. edge the tub done two-step die the H-P-M press. The curling die shown the hydropress Fig. 21. The unique feature that the edge curled two steps this one die set. The tub section first placed the press with its big end up. The upper die shape such and the press 90-deg. curl made the first stroke. The operation curling the upper method resistance seam welding the butt side seam galley fub The piece then inverted and the body fusing wire filler rod (suspended coil overhead) into butt seam. fed into place electrode wheels. Bottom the tub welded the same manner. Electric arc welding equally satisfactory but much slower. Turret Punch Presses has been set primarily for per presses, forating steel shelving. This machine, set 47). The machine equipped with ing rollers. Shape in. and with four special the she trolled the welded punches and two narrow heel steel jig, left, which body. punches are used for notching get rapid and accurate facture both | é die each tub die Cast nged and, ‘ions, rome flame tub pmann and with Tables Puneh with round ‘om unches square lay- the gage spacing holes stop fingers en- gaging the pins spacing bar with- out the necessity center punching each hole beforehand. along one longitudinal centerline are first punched, then the gage bar moved feed screw and micrometer dial setting for the next set holes. The sheet located against this gage bar and stop bar the left corner. The punches the turret lend the versatility this machine for the class work mentioned. The ma- chine capable making strokes per minute in. length. There also 12-ton Wiedemann turret punch press used without gages Close-up jig for holding galley tub proper position for rotation circle shear while trimming ends. Jig frame guided rollers (one each side shear head) running track sec- tion. 22—-Close-up 20-ton Weidemann power multiple punch being used with spacer perforate shelving provide lightening holes. This turret punch press equipped vitha pin type gage bar that holes can perforated using system and coordinates for layout directly from table. Hole spacing from the left-hand corner the sheet. for miscellaneous perforating opera- addition, two Consolidated Nos. and are set for corners, using and coor- dinate slides for speeding the lay- These two presses, together with the large Wiedemann, are used boxes with folded corners are later welded. High Production Work There are few jobs that come metal shop that are production nature. Some these machine with inverted slide. This machine generally tooled edge the lower simple blanking and perforating die. More elaborate progressive dies, the one used for the manu- badge clips, which involves perforating, blanking and form- tub body with the top edge roll com- pleted. The curl started the upper die, with the tub in- verted from the po- sition shown. The second operation ing and which incorporates wedge action for bending right angles the main slide strut, are put the press. Some simple types bending work are done Cincinnati and Niagara press brakes, making use the low cost welded forming dies “jigs” they are termed Bremerton. Such forms, which average only in. long, are cut out scrap ship plate oxygen torch the Doall band saw. Each half consists two main pieces arc welded together right angles each other. Several hun- dred these dies have been con- structed the matter few hours each and they are readily adaptable for short run work because their low cost, simplicity design and mounting. Safety paramount factor the ley Wire 4 sheet metal shop. Fig. shown new heavy-duty Niagara in. ft. shear recently installed. All the extra guarding put this machine was constructed the shop itself and typical safety practice through- out the Yard. great deal attention paid resistance welding sheet metal parts the Puget Sound Navy Yard. Seven spot welders have stalled the ground floor, including two Federal welders kva. capac- ity, two National welders kva. and one Thomson-Gibb butt welder kva. for welding butt angle straps and wire work. There are also two condenser type, stored energy ma- chines for aluminum work, one kva. Thomson-Gibb machine with Westinghouse trols, the other Taylor-Winfield kva. machine for heavier gages. Taylor-Winfield 200 kva. roller seam welder with Thyratron control and ABOVE 1G. Safety screens guards applied 4-ft. Niagara power shear, showing bar connecting the two with guard over the bar pre- vent accidental tripping. Note also guards over hold downs and shear blades and guards over the eccentrics the main shaft, both front and rear. RIGHT 1G. 24—Flexible arrange- ment 350 kva. Fed- eral spot welder and 200 kva. Taylor-Winfield seam welder with electric leads suspended overhead which permits machines moved about within lim- ited area. the rear form the front BELOW 25—Resistance seam welding method for making non-water-tight, ventilation elbows using copper alloy adapter se- cured kva, welder. These elbow halves are formed the drop ham- mer (see Fig. 8). Federal 350 kva. rocker spot welder with Ignitron contro] fitted with casters give degree portability. The panels are kept pad-locked off the side the shop and cable leads the machines are suspended overhead loops, Fig 24, that the machines can out into the center aisle for handling long work. Thus can seen that practically every type spot seam welding sheet metal can handled efficient. practically any gage and any material, including black sheets, stain. less steel and aluminum. This typ ing seaming, soldering and Incidentally, there are three gun spot welders use the outfitting docks for work the vessels thet selves. While much the spot and welding work done the tional manner, the special fixture seam welding non-watertight tion elbows, shown Fig. 25, innovation for this yard. the first part the article, facture these elbows represents the biggest production job the hammer. Hence was found while tool resistance welde fabricate the halves. Copper backing bar ares various radii attached the rocker arm oscillated under the seam wheel. There also corresponding change the the pivot point. cording and Technis large finds there. ing ha: been The quires steel; readily used For burners welding using same Sheet When oxygen one size the free fro being used, this mu: avoid With the gas 52—THE IRON AGE, August 26, 1943 ype are ited trol age the Fig. ling ding any tain- type plac- LUMINUM may welded either the electrical systems. and Zurbriigg the Swiss magazine Technische Rundschau, gas welding large scale Switzerland, and, still its most extensive application there. recent years electrical weld- ing has become commonly used for and great progress has made this connection. The gas welding aluminum re- quires more experience than that steel; nevertheless, the technique may used welding steel. For the gas welding aluminum, the same welding apparatus and burners may employed for the welding steel. Practiced operators wing oxygen and acetylene use the same nozzles. = Nozzle Sheet Thickness, In. Diameter, In. 0.02 0.04 0.03 0.04 0.08 0.04 0.08 0.15 0.05 0.15 0.27 0.055 0.27 0.47 0.07 0.47 0.79 0.09 0.79 1.2 0.10 then Over 1.2 0.12 When using hydrogen and oxygen, and oxygen butane and flames, the nozzles may ‘uggested that those inexperienced size smaller than those indi- The nozzles must always free from sooty deposits, the outside may cleaned with wooden stick Soft aluminum wire, the jet itself Where acetylene from generator the gas purifier attached must always well cared for sion avoid contamination the weld foreign matter carried over the gas stream; dissolved acetylene Welding Light Metals This Swiss article two Continental authorities gas, arc and atomic-hydrogen welding aluminum and magnesium and their alloys gives clear and practical directions for preparation parts joined and procedure and equipment for welding. does not give rise this difficulty. regards eye protection, the glasses worn should such den- sity that, normal daylight, news- paper type can still read. almost every case filler rod must used. few instances only, such where the edges thin sheet may turned up, held together and run down, where thin rods may twisted together and run down, the use the filler unnecessary. Recommended filler rod compositions are given Table Unalloyed aluminum tutes the principal material welded, particularly for vessels, boilers and containers various types. High- strength alloys are still principally assembed riveting, mechanical properties are destroyed heating during welding. suitable cases, deterioration mechanical properties which results welding high-strength alloys can, part, recovered heat treating after welding. This not possible the case large structural com- ponents. the moment, considerable atten- tion being paid improvement gas welding aluminum-copper al- loys. Nevertheless, has far proved impossible eliminate subse- quent heat treatment when high strength desired. The thickness the welding rod used depends the thickness the material being joined. Thus: Filler Rod Material, In. Diameter, In. 0.02 0.08 0.8 0.08 0.2 0.12 0.14 0.2 0.4 0.2 Above 0.4 0.3 For heavier than these, still thicker filler rod employed. When welding unalloyed aluminum and aluminum alloys, flux must employed. Alpax alone excep- tion this rule and may welded without flux, the skin the pool molten metal during welding be- ing broken and removed during the operation, with the filler rod. The object the flux dissolve the oxide skin from the surface the metal and protect the point being welded against access oxygen, that is, prevent becoming re-oxidized. Only when the flux has melted and covered the point welded found possible get metal from the filler rod adhere. Unsatisfactory fluxes may influence adversely the quality the weld, advisable employ only proved products from well-known concerns. warning this direction especially necessary the moment, because, Switzerland, welding ma- terials pre-war quality arc prac- tically unobtainable. Welding fluxes invariably contain lithium chloride, and this can longer obtained Switzerland, where efforts are now being made develop lithium- free flux. One such material (Lumi- weld has already appeared the market. general, welding with free fluxes more difficult than with those containing weld does, however, possess advantage unlike the lithium- hence easier store and handle. THE IRON August 26, | Actually, for some time now, non- hygroscopic fluxes have been avail- able containing place the chloride; sodium and aluminum fluorides have also been employed. Flux Made Into Paste The flux is, prior use, made into reasonably stiff paste with rain water distilled water, glass, china plastic container being used for the purpose. The degreased filler rod, and, where alloys are being welded, the edges the join, are covered with the paste. Edge-to-edge welds should always employed. Lap joints, unless their use unavoidable, present ad- vantages regards strength, and, any case, tend act traps for flux. According the thickness the metal, the edges joined should Sheets should not brought close into contact, but should separated that, during welding, metal from the filler rod can flow completely across the section. the case thin sheets, where the edges joined are practically parallel, the gap be- tween the edges should correspond approximately the sheet thickness; with thicker sheets gap 0.1 0.15 in. must provided. For weld- ing, thick sheets are placed that the gap between them tapered shown Fig. They are then tacked the narrow end the taper shown, the gap here being 0.08 0.12 in. wide. the wide end the taper gap 0.15 0.2 in. desirable. Welding commences tacked spot towards the bigger end the taper; afterwards welding taken again towards the smaller end the taper over the tacked spot, which again welded, and finally, the end the taper. Thin sheets are best tacked intervals about in., the tacked edges being then flattened with wooden hammer, and welding commenced before. Fig. trates the procedure adopted. For sheet under 0.03 in., ex- pedient turn the edges the 0.08 0.1 in. The opposing faces the turned-up edges are then brushed over with flux and brought together. The two sheets are now tacked shown Fig. after which the abutting edges are run down with welding flame, filler rod being used. Before commencing welding, areas ‘in the regions joined are first warmed with the torch, massive IRON AGE, August 26, 1943 (a) (b) (c) for welding: sheet between 0.02 and 0.08 in. thick; (b) sheet between 0.08 and 0.4 in. thick; (c) sheet and sec- tions a