The Iron Age 1943-09-23: Vol 152 Iss 13

uired) Presses only uction rcraft, radio, ratory erator ing read- are work 1943 SEP 1943 BACK THE ATTACK WITH WAR BONDS Prescription for Mechanized War THE “PILLS” shown above are bad medicine for the Axis. They are ball bearings. Multiply them tens thousands, daily, and you have the freedom from friction and wear which makes today’s mechanized war possible. Ball bearings, the tens millions, are used tanks, planes, guns, ships. Without them. sustained action destroying our enemies would impossible. Thus NEW DEPARTURE ball bearings— near perfection engineering science can make them—play their parts winning Victory! New Departure Division General Motors. __ \ ) | C0. Pa. full ped work THE FORGED STEEL BEARING HETHER your peacetime production takes again where left off—or strikes faster tempo you adopt new processes, incorporate new materials The correct application pow- vital importance. With your first need for worm gear speed re- ducers, write into your specifications. You can in- stall Clevelands and forget them —just you have for the past years. For your equipment from boiler house final inspection, Cleveland supplies Worm Gear Speed Reducers standardized unit types, correctly designed and precision-built. For contin- uous heavy duty—single multiple reduction—any size— any ratio. you need send your prints. Dependable Cleveland Worm Gear Drives will help you look with confi- dence into the “tomorrow” your manufacturing operations. 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. (INC.). Entered second class matter November 1932, the Post Philadelphia under act March 1879. $8 yearly in North America and South America. Foreign $15. Vol. 152. No. 13. fie VAN President and Editer BAUR Vice-President General and Advertising Offices East 42nd St., New York 17, Baur, Typography and ° Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd Cleveland Pittsburgh 1016 Guardian Bidg. 428 Park Chicago Chilton 1134 Bidg. PEIRCE LEWIS WARREN 7310 Woodward Ave. Box RAYMOND KAY Los Angeles 2420 Cheremoya Ave ° ° Owned and Published CHILTON COMPANY Executive Offices Chestnut and 5éth Sts., Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, JOS. HILDRETH Vice-President GEORGE GRIFFITHS Vice-President VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary CHASE THOMAS KANE HARRY DUFFY CHARLES ° Member, Audit Bureau Gear treet, Member, Associated Business jon mited ° ° Indexed the Industrial Arts index, lished eVery Thursday. Subscription North America, South America and Possessions, $8; Foreign, $15 Single Copy, cents. Number, ° 1943. Chilton Company Yftice at Vol. 152, No. AGE Editorial Why Can’t Have It? Technical Articles Silver Alloy Brazing Heat Treater Looks Tool Design Screw Machine Steels Alloy Steel Substitutes Centralized Grinding for Single-Point Tools Effects Cold Drawing Welded Steel Tubing Making Carbide Tipped Flat Boring Cutters Pressure Welding Heavy Tubing Induction Heater Speeds Tube Forming New Equipment Features News Front Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets Iron and Steel Engineers Discuss War Problems OPA Amends 250 Price Orders. OPA Completing Advisory Set-Ups Broadened Loan Plan Aids War Contractors Personals and Obituaries Machine Tools News Non-Ferrous Metals News and Nen-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Prices 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 September 23, 1943 = 106 108 114 118 134 136 138 139 140 142 143 144 145 145 148 149 150 195 | ° ° 34—THE IRON AGE, September 23, 1943 RYERSON STEE ACROSS COUNTR Tons Sheets Delivered 700 Miles 4:10 P.M.—a truck with ten tons sheet steel pulls away from the Ryerson Chicago plant. Western war factory 700 miles away, important production for Army invasion equipment waiting. Flying the ODT with special permission travel miles hour, the shipment arrives the next day 11:30 hours and minutes after the order was dispatched. Two significant facts: The sheets urgently needed were Ryerson stock for immediate shipment. And Ryerson facilities and service measured the emergency. Unusual? No! This order only one many Ryerson emergency shipments that are pre- venting production shut-downs these criti- cal times. Every day, Ryerson skill and expe- rience are expediting deliveries vital steel. Next time you need steel hurry, whether sheets, plates, bars urge you call the nearest the ten Ryerson Steel- Service plants. Whatever you require, you'll prompt, effective cooperation. Joseph Ryerson Son, Inc., Steel-Service plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Bos- ton, Philadelphia, Jersey City. | | | | | IRON AGE ESTABLISHED 1855 Sept. 23, 1943 ° ° VAN DEVENTER President and Editor BAUR and General Manage: DIX Manager, Reader Service News, Markets Editor...D. JAMES Technical Editor......... OLIVER Associate Editors PHAIR MacDONALD BARMASEL BUTZNER Editorial Assistants SCHIEN WILLIAMS BUTTERS. News and Technical Editors CAMPBELL Pittsburgh 428 Park Bldg. POST Chicago 1134 Otis MOFFETT Washington Press Bldg. 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 Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle Why Can't Have ET’S consider our postwar problem objectively. With million our most capable potential producers the armed forces and hence out the production picture, are producing volume goods this country well over per cent greater than pre-war per capita consuming power was capable supporting. When those these million who survive return, where are their jobs coming from? Federal Works Administrator Philip Fleming has asserted that this country must place upon the government its chief reliance for high employment after the war. Here high authority doffing its hat regimented future economy. But how can even government hope finance consumption and hence employment high level when since 1932 has been putting into the hole debt progressively increasing rate which measured $30 million mile would bring out China—and its standard living—some time early 1945? No, government can’t keep that wolf from our doors. The only thing that can for private enterprise, working self-liquidating, profit-making basis underwrite adequate postwar employment. Good men. are working that problem. The Committee for Economic Development, which headed Paul Hoffman, for example. These experts have figured that private enterprise the job, will have find way move per cent more goods and services than were moved before the defense and war programs began. course cannot hope start out the day after peace de- clared and sell per cent more than did before the war began. Certainly not the line industrial equipment. Government will have help bridge the gap for period perhaps two five years. Bridging the gap going even deeper into the hole debit financing production. The most ardent advocate private enterprise versus government bureaucracy recognizes this fact. The big point that during this interim, government should help finance private enterprise, not compete with it. And that government should have the intent withdraw from activities foreign pure government and shift the burden private industry just fast the latter able shoulder it. What not want government have the intention increasing and not diminishing its functions employer. The expression such intent, authority even higher than Administrator Fleming, something that this country needs today. Why can’t have it? | | | | | ° ° | | | | | ° ° ° | | | | | | | | | | | | } | This temporary bridge the upper River will replaced steel spa Bridges Japan “Bridges Japan” are being fabricated from Inland plates and shapes, and shipped, along with Inland sheet piling, sites the 1670-mile Alaska Highway. Pushed through record-breaking time, this stra- tegic highway now being completed for the transpor- tation important military supplies our Alaskan outpost. The original bridges and piers the highway were built largely timber from surrounding forests. These temporary structures are being replaced now bridges steel. The new permanent bridges are built not only withstand heavy military traffic during the war but ‘to assure safety when the highway opened com- mercial and tourist traffic later. These “Bridges Japan” are but one the many ways which Inland steel used helping win the war. INLAND Milwaukee Detroit St. Paul St. Kansas Cincinnati New York er spar 1943 Illustrating changes production emphasis caused the fluidity war the listing the mm. gun critical item. Maximum output has just been ordered, the result experience Sicily and Italy. Sicily, percent these anti-tank weapons put into action were lost. The Thompson sub-machine gun being replaced the gun for general combat use. The constructed stamped metal parts except for the barrel and firing mechanism, and its simplicity design and operation resembles the British Sten. Best down-to-earth estimate battle scrap imports for the remainder the year 20,000 tons month. The excellent scrap yards Sicily and Italy could well used prepare battle scrap prior shipment here. This would save ping space, labor here, and would give work demobilized Italians. Maritime Commission has goal percent women shipyards, about equal the British level. One Portland yard, far ahead others, percent. Experiments with green sand molds for centrifugal castings are opening new possibilities substantial cost reductions spun castings. Labor people consider one the sharpest stings the law the prohibition against political contributions unions. One radio station, extreme interpretation, has denied UAW vice-president Richard Frankensteen paid radio time for political action speech. Government spokesman's recent widely publicized statement that the U.S. turning out more aircraft all the remainder the world put together may good propaganda. U.S. production is, it's still far that good. All American combat units are now supplied with the shorter, lighter and sturdier bayonet, which measures in., compared with the previous in. The new bayonet 362 tons high carbon steel 1943, and estimated 560 tons 1944. U.S. Fragmentation bombs are built steel cylinder containing TNT, around which wound rectangular iron rod, which exploding breaks into about 1500 pieces (last war's cast forged fragmentation shell broke into 300 pieces), about 0.3 oz. average weight, having velocities 4000 ft. per sec. And: Each bomb carries parachute enable low flying bombers escape the fragments. The greatest demonstration such parachute bombing was the Battle New Guinea, when the Japanese were cut pieces the Owen Stanley Range. Composite wooden aircraft used the Russians were recently analyzed and commented the German magazine Luftwissen. Exceptionally high tensile and compression figures were obtained for compacted birch spars bonded with resin, taken from the Russian single-seat fighter. the past year's rate, will take Smaller War Plants Corp. just about six years lend small business the first round its $150,000,000 capitalization. The 462 loans made since last October total $22,354,858. The alloy steel turnings problem remains unsolved, with 55,000 tons the 140,000 tons produced month lost through improper segregation. Present inventory alloy steel turnings three-month's supply; WPB would like make German economists, recent articles, have frequently used the phrase "Die Decke ist kurz" ("The cover too short"), subtle phrase not too hard morale, but which means lack even scarcity materials. recent survey German aeronautical potential came the conclusion that new types aircraft can expected this war. Luftwaffe type policy has for some time been towards the Fighters are designed and used light bombers; bombers night long-range day fighters, etc., etc. German people are beginning ask, "Where our fighter reserve?" gandists, anticipating this question, are beginning talk the enormous output over the past year, and introduced carefully conceived mouth-to-mouth Campaign large fleets airplanes "somewhere Germany" waiting for "The > ; = combination silver alloy brazing with fast, localized heat- ing supplied recently devel- oped ceramic gas-air burners makes possible new, swift, continuous, cheap method joining metals, method flexible and adaptable enough use economically both products made large quantities over long periods time, and products subject frequent redesign short con- tracts. Techniques and equipment for this method production-line joining have largely been worked out during the past year items. The essentials are: time, tempera- ture, the placing and control heat sources, and (in order not damage the metals being joined) brazing 38—THE IRON AGE, September 23, 1943 alloy which melts uniformly rela- tively low temperatures. The burn- ers used for the brazing methods described here are new Selas types assembled from precisely molded cer- amic parts remarkable refractory and insulating qualities, and supplied with accurately premixed city gas and air under pressure. The brazing al- loys used are Handy Easy-Flo, for joining ferrous, non- ferrous, and dissimilar and Sil-Fos for joining non-ferrous alloys exclusively. example the method applied parts limited production the work done Lightolier Co., Jersey City, makers marine lighting fix- tures which must able withstand the vibratory shock caused 16- in. shell. Fig. shows the com- pany’s fixture parts, with total brazed joints. Lightolier estimates that radiant and superheat gas heating methods have quadrupled production cases where other methods had formerly been used, although many the joints were never attempted any other way. The company’s localized gas heat- ing equipment consists six largé radiant ceramic-cup burners, small superheat burners, six manifolds smaller ceramic-slot burners line, and one gas and air mixing machine capable delivering 3500 cu. ft. per hr. carbureted combustion mixture lb. per sq. in. pressure. Figs. and show two the principal production methods used. The large turntable (Fig. 2), which emer- gency construction with transite top supported cut lengths plumbing pipe furniture casters, has stations sets four, with three 120 deg. moves making complete cycle. While four parts are being brazed under the four radiant burn- ers, four are cooling and four are Marine parts, showing brazed joints made with one flex- setup. These parts must able the vibratory shock caused shell. ing pos jigs tior bre whi coc anc pla loa sen bra are wit 185 cu. for did eve B | rine ure ints flex- tup. Speed Localized Gas Heating being unloaded and loaded. loads, unloads and turns the table One girl with indexing stop. Three girls as- semble the parts and apply flux and brazing alloy. The parts (A, and Fig. are brazed the rate 300 hr., with output for the four girls about 1850 hr. day. The brazing itself takes sec. Stations are jigged take several models work-pieces. The burners for this table use 300 eu. ft. gas hr., fuel cost 15c. hr. With induction heating, which was formerly used for certain these parts, brazing took sec., one part was brazed time, and two girls did 560 parts day. The company also uses two the small turntables (Fig. each with six ceramic-lined superheat burners evenly spaced around the circumfer- ence. The burners are supported laboratory ring stand fixtures, and 2—Large turn- table used braz- ing marine lighting fixture parts, either positioned slots held special tions. Four parts brazed time while four others cool, and loading and unloading takes place four other stations. ° ° ° BUTZNER Associate Editor, AGE ° ° ° Gas-air brazing, with advantages fast localized heating and exceptional flexibility, has been widely developed during the past year war production items. Techniques and equipment for this method swift production line joining are here described. that their heating slots are any angle, and moved nearer farther from the part being brazed. One girl operates both tables, with two girls, most cases, preparing the parts for brazing. The part being brazed Fig. (F, bulb protector with six legs, all simultaneously brazed the support with the turntable kept sta- tionary. The legs are set into holes the ring, jig required, and brazing accomplished sec. This contrast another type protector (D, Fig. for which the legs are set directly ring, rather than holes, making jig necessary. Absorption heat the jig extends brazing time about min. brazing protectors the first type, with the heavy base, the burn- ers are directed the base below the braze, partly prevent blowing away the tiny brazing alloy rings, but mainly bring the heavier base section proper heat equally rapidly the light leg sections and the brazing alloy itself. all cases brazing with aimed localized. heat, this impor- tant factor. has solidus 1160 deg. F., liquidus 1175 deg. necessary not only for the brazing alloy reach brazing tem- THE IRON AGE, September 23, eS at- ge all ne, ine er ire gs. “ge er- ing ree ete ing rn- are RIGHT pose machine for brazing and anneal- ing incendiary bomb cases. After passing through pre-heat zone where the flux dried, the assemblies are brazed 1200 deg. subsequently reaching 1450 deg. F., point in. down from the top the case, for an- nealing. The bottom few inches the case are not af- fected. a perature, but also for the metal both sides the braze reach it, and practically simultaneously. The same principle holds, course, for brazing alloys with higher lower melting points. Because this, the burners are rarely directed precisely the braze itself, but rather the heavier the assembled sections. For the same reason, the distances burner faces from the assembly joints are frequently differential, examples which will shown later. 40—THE IRON AGE, September 23, 1943 LEFT 3—One pair small turn- tables tended one operator. dling this piece the table stationary while the six radiant gas superheat burn- ers are directed six protector joints. other cases part rotates Wherever possible, the use jigs should avoided because heat absorption, illustrated the two types bulb protectors referred above. Where jigs are necessary, they should designed minimize heat absorption. example such jig that used for cover box (H, Fig. 1). Here two brazes are done once the same assembly, the small turntables being used. The base the assembly the steel cover base, top which the steel box, surmounted threaded brass All three parts are placed and around steel jig consisting base and center column. The jig base that cold metal does not lie under the bottom braze itself. The jig center column deeply fluted for minimum contact with the parts being located. Two burners are directed the top braze, for which ring Easy-Flo brazing alloy The other four burners around the turntable are set angles around the bottom braze, which brazing alloy wire hand fed. The two top burners are pulled back in. farther than the four bottom burners both because the lighter section and the better heat conductivity brass. Both brazes are thus com- pleted simultaneously, rate about assemblies hr. Another typical operation done the small turntables the brazing three machined posts socket cover (M, Fig. with brazing time sec. instance part which all brazes are not done once that alarm bell housing plate Fig. 1). the top side this part, shown the photograph, malleable iron forging brazed 3-in. stan pre top. for are supe ster whe stuc lyin the hele £0 mi CO pr ra and jase not The for top ‘ing sed, the und top ther tion cover all that part, eable About stamped steel case sec. sq. in. surfaces are brazed. previously applied boss, also brazed, the underside the stamped part not melted off during the brazing the forging because the underside the piece remains cooler than the top. Another scheme assembly used for ratchet swivels for desk lamps (P, which are held eight time rack while the two screw studs are brazed holes. superheat burners manifold are held angle against the swivel below the where the metal heavy. Axial studs are brazed with the parts lying flat row transite slab, the same manifold with eight burners held over stem sides, the opposite pole from the Light- emergency ment the Selas built dual purpose automatic machine (Fig. used Stanley Works for brazing drawn assemblies into the ends hexa- gonal seam-welded steel tubes and simultaneously annealing the cap end the upper half each tube. The machine, used this instance the continuous straight-line production incendiary (oil) bomb adapt- metal Ninety-two radiant cup gas burners stud the walls and roof remov- tunnel, which lets down over progressing line individually rotat- pieces. The bulk the heat work, with minimum loss through in. wide bottom slot opening. Only min. for heating the unit start production required. Each the parts weighs about lb., which lb. heated. The present production rate, using only every other station, 600 hr. gas cost about hr. production rate 1200 per hr., has been shown practical. The assembly consists heavy outside hexagonal tube in. across flats, the top which inserted thin-section hex- agonal, open topped cup. Inside this inserted thick-section, open bot- tomed cup, the two cups forming cell capsule about in. deep. The work prepared inserting the cap assembly into the tube end after flux- ing, then laying brazing alloy wire ABOVE 6—Brazing ce- mented carbide tip tool. Each the two burners uses cu. ft. pre- mixed city gas and air per The un- assembled parts, in- cluding cut and shaped brazing alloy shims, are shown the lower right hand corner. ENSILE STRENGT top the joint. the pre-heat zone the flux dried does not boil and spatter burners. After the assembly into the heating zone and has attained 1200 deg. F., the brazing alloy flows into the joints either side the thinnest drawn cup. Fur- ther the heating zone, 1450 deg. F., the entire assembly and tube are annealed point in. down from top. Thereafter slow cooling oecurs the point where the parts are manually removed. The application the brazing alloy this assembly particularly note- worthy. Two shaped Easy-Flo wires, each slightly longer than half the top circumference, are placed the joint that their ends overlap one an- other. The overlapping occurs point where excess brazing al- loy desired because the assembly wall subsequently drilled and tapped that point for insertion explo- sive. should noted that all cases, joints silver alloy brazed should closely fitted. Fig. shows the relation joint thickness tensile strength (based butt joints stainless steel) and indicated the curve, joints thickness about 0.0015 in. achieve maximum strength, with joints 0.003 in. thick- ness highly satisfactory. instance which localized gas heating with six Selas ceramic-con- fined-combustion burners solved rather baffling production problem was the assembling bronze deck drain pots for ships. was neces- sary braze steel ring in. section ‘around the top in. diameter pot with in. cast bronze wall. When was attempted braze the assembly whole-part heating within furnace, the two joined sections pulled apart cool- ing. There divergence opinion whether this was caused RIGHT 1G. Relation joint thickness tensile strength, based silver brazed butt joints stainless steel. = 5 | 4 q it 0. 4 f THE IRON AGE, September 23, 7 fillet. cu. ft. gas per hr. ferential expansion the metals (and consequent stretching the steel ring) during heating, whether not enough was used for the pro- longed furnace heating. None the less, the parts are now being satisfactorily 42—THE IRON AGE, September 23, 1943 1G. 7—Brazing bracket web marine lighting fixture. The photograph shows instant fusion brazing alloy. Position burners, in. from valley, important avoid formation heavy Each ceramic-lined superheat burner uses brazed sec. each, during rota- tion, within ring high-speed local- ized heat sources. technique heat application which single radiant-cup burner 8—Brazing radiating fins heat exchanger tube. The used the combus- tion chamber. The spear flame burner, unit lying brick) uses cu. ft. gas per hr. placed under, and completely sur- rounded by, the part being brazed has been used American Meter Co. Here in. cast steel nose adap- ters are brazed gage steel noses incendiary bombs. After flux applied around the hole the sum- mit the cup shaped nose, both the adapter and the alloy ring are pressed into place. Pressing the brazing alloy together with the adapter facili- tates the “running in” action the braze. over the burner for sec. One girl prepares parts, another burners, with production 1000 assemblies 8-hr. day. After brazing, oil 400 pres- sure and 120 deg. F., applied against the inside each nose, which raises the flattened apex without the braze giving. Only 0.1 per cent 1000) leakage joints has been found. experimental setup for silver alloy brazing with gas heating used General Electric Co.’s Phila- delphia plant. The apparatus con- sists diameter ring mani- fold supported four ble tubing connects each ten super- héat-slot burners the manifold. Burners are held arms with uni- versal couplers, permitting raising, lowering, horizontal movement, twist- ing, and setting angles. The ap- paratus sufficiently flexible that almost any part can brazed experimentally. This company has done consider- able work brazing circuit break- ers which have been newly designed use less copper. one instance, heavy bar copper coils are brazed two copper terminal blocks, one block jig grips the small terminal block horizontal position; the large 6-in. block jigged vertically. The jig which grips the small block comes contact with the braze and hence covered with compound keep the braze from penetrating it. Two small burners are directed the small block; one big and two small burners the large one. The braz- ing time sec., with sec. for cooling. Timing automatic. The burners are held rigidly and the assembly the jig slid between them guide rail. For- merly the brazing was done with hand torches, one braze time, fourth the present production rate. necessary silver plate sections the two blocks. Practically the only way this after assembly The assembled nose placed silv pli en mi m sur- razed Meter adap- noses sum- the essed azing the laced girl the 1000 pres- rainst raises been silver Phila- con- mani- uper- ifold. ising, ap- that sider- igned block block large The hence keep Two the small braz- for The sition, slid silver plate the whole part. However, has been found possible plate the sections the two blocks before assembly, even though one point the plating actually comes contact with the subsequently made braze. Blistering prevented chilling the plated part, while brazing takes with heavy block steel internally water cooled. Simultaneously with brazing, the coils these assemblies are annealed that they can moved more easily for applying insulating coating. The blocks are not annealed. When other types coils are brazed, course other jigs are used and the burners are differently direct- ed. Hence the whole assembled braz- ing unit, including burners and guide rail, designed lifted and out the working table. main carbureted gas-air supply pipe makes one connection with the entire burner assembly. General Electric Co.’s Pittsfield plant, relatively massive piece work the brazing brass and cop- per rods brass end plates for motor pole pieces. The end piece in. thick, seven middle rods are cross- section in., and two round end rods are 9/16 in. diameter. The three center rods are copper. For making these nine brazes are used above, and one below, the endpiece. roving superheat burner moved the operator and where needed accelerate braze fusion and flow lagging points was first installed, but has not been necessary. Brazing rods one endpiece takes min. The jig holding the rods and endpiece swivel, and when brazing one end finished, the jig swung around, bringing the other end the assembly into position for brazing and dunking the brazed end into quench tank. The whole operation, including assembly the jigs, takes min. some cases the rods spring little, leav- ing hole between the brass plate and the bars, which filled later with acetylene torch and stick alloy. This touching requires about With the use city gas the new high-speed setup, the fuel cost for complete pole assembly 1.96c. Cost acetylene, including handling cylinders, was 19.4c. for com- plete pole. This concurs with records from another manufacturer steel products who reports 4c. fuel cost per 100 joints with gas-air production setup. Another use which the radiant gas method brazing has been put the replacing worn cemented 1G. steel bushing and bronze bushing simultaneously brazed steel electric control box cover. indicated the dotted lines, faces burners are held in. above work prevent too rapid heating and warping cover. Each the six burners uses cu. ft. gas per hr. carbide tool tips. The technique used, which was developed Selas Co. and the central tool department Mid- vale Co., Philadelphia, illustrated Fig. which also shows the lower right hand corner the two 10—Heat exchanger tubes being joined heavy cast header. The photograph, taken the instant fu- sion the brazing alloy rings, illus- trates which the entire heat directed the heavier the two joined Each the four superheat burners uses cu. ft. gas per hr. pieces shaped brazing alloy sheet used. small tools the vertical strip alloy generally omitted. Midvale reports can now remove worn carbide tool tip and-replace with new one three four times quickly any previous method. Fuel costs have been reduced per | it q = to THE IRON AGE, September 23, 1943—43 cent. some instances temperature bronze bond used lieu silver alloy, arrangement made possible because the intensi- fied local heating. all instances which the radiant gas heating burners are used, the extremely high rate heat transfer obtained using high pressure fuel the burner, combusting fuel multiple jets along accurately shaped ceramic surfaces which attain high incandes- cence, compacting the combustion into small space with impingement the burning gases until combustion complete, and the exclusion cool- ing and diluting secondary air from the combustion gases. Midvale noted that because the velocity the burn- ing gases largely dissipated within the burner cup, there blasting over the tool. Time for brazing the tool tip shown Fig was The distance the burner faces from the work in. For odd shaped tools, the burner spacing the two sides may unequal that the whole surface attains brazing temperature the same instant. For the tool illustrated, 0.005 in. thick Easy-Flo was used. Fig. illustrates particularly well the necessity for the proper direction heat. The stock thickness for this part, marine lighting fixture bracket web, gage, and the braze superheat-slot burners are held along joint part for celebrated the line the braze, in. away from the valley where heavy waste- ful fillet silver alloy would collect the valley were directly heated. With uniform heating, the two hair- pins 1/32-in. diameter Easy-Flo wire fuse all once. The same part less economically brazed another heating method, shown Fig. Note the heavy silver alloy fillet. Fig. illustrating the brazing fins heat exchanger part, the heat exchanger tube itself used the combustion chamber, with out- let into refractory enclosure which adjustable that even heating along the length the tube at- tuined. The stainless steel in. O.D. and 1/16 wall. fins, stamped from 1/32-in. stainless steel stock, have in- ternal flanges space the fins auto- matically, hold them during brazing, afford good fit for metal flow over the entire tube area. The brazing rings are pre-formed 1/32-in. diameter Easy-F lo. ceramic-port spear flame burner used; the spare unit lying the brick shows the port construction. Brazing time sec. After brazing completed, the tube has reality three walls; the tube itself, the uniformly distributed brazing alloy, and the fin flanges. Bronze steel and steel steel ure brazed simultaneously the gage steel electric control box cover shown Fig. The large bronze The brazing alloy ring set the groove the solid plug, indicated the unassembled parts. When braze finished, bead visible all around base the groove shown the assembled making lap joint. The two top burners use cu. ft. gas per hr. the two bottom burners cu. ft. each, instance individual burner adjustability compensate for irregularities heat loss. 44—THE IRON AGE, September 23, 1943 bushing has flange top, but the small steel bushing bottom flange, making necessary peen crimp marks four points around the hole grip the bushing against gravity during brazing. use, the face the compact radiant burner nest six cups in. above the work, shown the dotted lines, that heating will not has too rapid and warp the cover. Brazing time 105 sec. Preformed 1/16-in. diameter were used. Fig. 10, taken the instant fusion brazing rings, shows heat exchanger tubes being joined cast header. The thick casting with press fit holes, having more mass than the 1/16th-in. wall tubes, di- rectly heated, while heat di- rected the tubes, making pos- sible for both the casting and the tubes reach brazing temperature the same instant. The four burner slots are held in. from the ing. interesting application braz- ing alloy shown Fig. 11. The diameter Easy-Flo wire, pre- cut into the solid plug. To- gether with the plug, inserted into the tube. Capillarity flows the brazing alloy along the cylindrical joint surface until the head visible all around the base the groove, the assembled part, thus making lap joint. Two burners are directed the plug, above the groove, and two the tube, below the groove and toward the joint. The two top burners use cu. ft. gas per hr. per burner, while the bottom burners use cu, ft. per burner, example compensate for irregularities con- ductive heat loss. The slots are in. from the work, which r.p.m. Brazing time see. Over and above the cited, modern gas-air brazing, with the all- ceramic “accelerated-combustion type burner illustrated herewith, used braze the trailing edge hol- steel propellers, intricate joints pilot tube assemblies, can- nister heads, and dozens assem- blies formerly riveted, threaded and screwed, welded, spun consider- ably lower speed and higher cost. In- dustrial imagination will range wide fields conceiving future simply “laying up” component build- ing blocks and letting controlled localized heating bond the final unit product. cases fess har ploy one eve leac mat mus kno tool job tool des the are diff cou fra Sti sar of site stil sec tool fina achi and orel the hole avity the not over. rmed rings heat sting mass di- pos- ature irner cast- braz- The essed To- erted the lrical isible ‘oove, the ward s use indi- con- tated sec. cited, all- type hol- ricate can- ssem- and sider- In- build- rolled unit realize that all the tools de- signed and started through the tool room, very few ever succeed finally reaching the job and there achieving the maximum productivity and life. guess that the figure not over per cent. From the standpoint the pro- heat treater who daily hardens many different steels and em- ploys wide variety treatments, one can see that chain minor events, each insignificant leads loss manhours and scarce materials which the aggregate must appalling the total were Theoretically, someone designs the tool, selects the right steel for the job and then sends the job the tool room. Occasionally, fear, the designer does not dwell very long the fact that light and heavy sections are bound expand and’ contact different Some loss counted for distortion, even fracture, such oversight. Still less often considered neces- sary pieces varying section protect against cracking the use fillets, drilling hole oppo- site sharp corner, what may still better making the tools sections. the selection tool steel, there simply for calling for case hardening where the steel con- tains very much carbon, steel for delicate tools when there are many varie- ties oil hardening tool steel, choosing alloy steel that never was intended heat treated the high degree hardness specified the blueprint. for making stampings out cold rolled strip, and expecting the heat treater wave magic wand and Only too often such things happen and add the total waste. But there far greater cause waste existing today than any these. due the fact that fessional Water Heat Treater ooks Tool Design ° EVES Chief Field Engineer, Perfection Tool Metal Heat Treating Co., Chicago many tools nowadays are made one department and hardened another, are sent out commercial heat treating plants like our own. ever-widening gap between the man who makes the tools parts and the man whose responsibility harden them the serious condition which gives rise tremendous loss labor and material. our plant harden couple tons high speed each day, and perhaps tons other tools. are highly conscious the fact that order produce the best possible job, first must know the analysis the steel every tool. But for have been confronted with the fact that the tool maker often doesn’t know, mixup oc- curred, and the information given with the job per cent cases either missing, or, worse yet, incorrect! Hundreds jobs are received with- out any kind steel being designated. Here the only loss delay, but course delays are not something easily countenanced these days. They may felt among the fog-bound rocks Attu the mosquito ridden jungles New Guinea and paid for human blood. But let disregard all that, and deal with the hundreds cases where are handed treat and are told that made from certain make and brand steel. The job may simple punch and die may 40,000 vital war parts. treat according what the customer says is. Obviously can’t smell it, nor taste it, nor see what kind steel may be. Nor sparking safe guide, since there are for example certain oil hardening steels that throw spark exactly like straight carbon steel. The trouble begins when quench that job and find out later (Oh how much later!) that was entirely different kind steel. The job may come out soft. more than one piece, the hardness may vary from one another. may burned crisp because far more heat was used than the steel ever was intended stand. Lots the jobs must re-treated again and again until some treat- ment found that will approximate the specifications. But mark clearly, those tools can not possible though properly hardened the first time—while those which have been subjected excessive heat probably are never put work all. One begins see, least, why tools made from the same steels and used idential fashion, often give widely different production figures. have said that about per cent all tools made ever reach the job and the maximum. From experience we've had during these past three years hardening high speed, even further and say that not even per cent high speed cut- ting tools attain the utmost results. Last year $400,000,000 worth such tools were made; figure out for Most the loss preventable. Standing here the midst stream tools from all directions, can see that some firms seldom err while others are constant offenders. There are thousands steels, and hundreds treatments. For every tool and every job, there one best way. are really get serious about this job conserving manhours and metals, some real thought should given the following points: Design tools and parts they only will the job, but also (CONTINUED PAGE 130) THE IRON AGE, September 23, 1941—45 | ° ° 7 g ovel uture crew Machine medium carbon screw ma- chine steels, due their high manganese content, are com- parable hardenability with alloy steels rather than with plain carbon where their use larger sizes re- quires water quenching. The high percentage sulphur the medium carbon screw machine steels will, course, have the same steels. The danger cracking detrimental effect the transverse water quenching is, therefore, re- mechanical properties did the moved except low carbon screw machine steels. COARSE GRAIN @. 35™ 17—Effect carbon content and grain size the harden- ability medium carbon screw machine steels containing 1.57, 0.08 0.14, 0.02 0.26, normalized 1650 deg. end quenched water from 1550 deg. Due the higher carbon and man- ganese content these medium car- bon steels, the silicon content not important. rare that medi- carbon screw machine steel will Silicon said some have detrimental effect the free ing properties. certainly true that the silicon present, silicate inclusion, will have abra- sive effect the cutting tools. How- ever, order obtain steel which has consistently sound ture, that is, steel that will meet deep etch test requirement, silicon content 0.15 0.30 per cent de- sirable. survey 121 heats steel failed show any increased hardenability segregation into two groups, one representing steels con- taining under 0.15 per cent silicon, and the other which contains 0.15 0.30 per cent silicon. The medium carbon screw machine steels given the American Iron and Steel Institute 1943 List are shown Table IV. Whether they should specified with ASTM Grain Size grain size not im- grades. The austenitic grain size test 18—Comparative hardenability medium carbon, sulphur- ized carbon, carbon and alloy steels. End quench tests, based J-45 value. COOLING RATE°F PER SECOND 1300°F. 100 HARDNESS w TESTED 46—THE IRON AGE, September 23, 1943 NUMBER 19—Frequency distribution curvé for heats 1137 steel, normalized 1650 deg. end quenched water from 1550 deg.; austenitic grain size 1700 deg. F., coarse; analysis, 1.26 1.57, 0.076 0.140, Si. 0.02 0.26. COOLING PER SECOND 600 200 100 70 60 50 40 30 PERCENT TOTAL ELONGATION IN 2~ ing pre she fin sib sile lat gra are obt cal too tur tre abi Harvester Co. from the same viewpoint. made carburizing specimen Medium carbon screw machine steels, their heat treatment deg. for hr. and slowly cool- and their hardenability comparison with that alloy steels ing very satisfactory test the here discussed the second section two-part article. Last not size happens fine 8), week carburizing grades screw machine steels were discussed but the test shows coarse grain this merely signifies that the ° ° ° probability high that the steel will meet The effect grain size the ten- sile and impact properties discussed two have lower hardenability than coarse con- grained steels. Fine grained steels are undesirable for screw machine 0.15 work the fine grain size has been obtained aluminum additions, be- cause the abrasive effect alumi- and num oxide inclusions the cutting the other hand there more ize definite guarantee that coarse struc- test The effect grain size the DISTANCE FROM END-SIXTEENTHS INCH hardenability well the effect distribution curve for heats AISI 1045 the carbon content illustrated fine grained steel, normalized 1650 deg. F., heated 1550 ability the screw machine steels 0.83 average; Si, 0.19 min., 0.29 0.22 average; Cr. 0.00 and plain carbon and alloy steel min., 0.10 max., 0.05 average. 6 10/2 1550 deg. and quenched oil, tempered indicated temper- 1550 deg. and quenched oil, tempered indicated temper- standard round tensile test specimen. Analysis: 0.23, atures; standard round tensile test specimen. Analysis: 0.46, eg. THE IRON AGE, September 23, 1943—47 i JAMESON Works Metallurgist, International | | | nm ROCKWELL y to} + 250000 200000 125000 Tensile properties held min. 1550 deg. and quench- oil, tempered; standard test specimen. Analysis, YIELD POINT POUNDS PER shown Figure 18. data Fig. into terms sizes, gives the data shown 0.21; austenitic 7 | grain size 1700 20| deg 75 100 125 150 175 200 225 250 275 TENSILE STRENGTH x 1000 4 20+ + + + 700 800 900 1000 1100 tensile test speci- 125000 men. Analysis, 0.46, 25000 as 15 20 25 30 35 40 45 50 $5 ROCKWELL x ad 1137 ture hardness, Rockwell oil quench and tempered, used. 158 600 700 800 900 1000 1100 1200 TEMPERING L200¥F CURVE DERIVED FROM ANALYSIS 128 17 3 AGS ATI NOO (700°F |HEATS ROM ANALYSIS RANGE! 35- 38/1 39-155 OARS 14 demand has been found from plotting frequent distribution curve from heats AISI C1137 steel, that variation hardenability greate than for plain carbon AISI This illustrated compar. ing Fig. with Fig. 20, and perhaps accounted for stating steel. that most screw machine steels not made according special ment quality practice, which less control exercised the ste mill practice. This turn mos likely due the lack the custome for screw machine with uniform heat treatment formance. Stee, pe Tensile Properties The tensile properties from fully hardened and temper AISI and AISI C1141 steek are shown Figs. and 22. term “fully hardened” that the section hardened outside center before tempering 99 — Figs. and the properties are shown the conver tional manner. The mode the physical properties not, fro the engineer’s view point, the desirable. would more base the graphs the tensile strength shown Fig 99 and 24. as Tempering Effects using these tensile charts, Translating the must also considered that they not strictly true for all heats The variation one point vious graphs shown Figs. 26. comparison AISI C1137, plain carbon C1050 and alloy steels and 9440, shown Figure 27. noted that despite the high C1141 steel shows greater loy steels would expected, show resistance than the C1141. The relationship tem strength the Rockwell steel, C1050, and alloy NE9440, shown Figure 28. all medium carbon steel hardened (45 Rockwell from outside the as-quenched and tempered have the tion) and NE9440 ther men stre valu Figu hard have rang are ever Rock desig sider hard size tion was state exte grail ues. high well, are carb ness valu deg. toa are § the size value quen and hard give) Was tigat artic hote¢ hig | j 250 80 TEM PERING TEM | i YP. | | | | PREAD DERIVED | 48—THE IRON AGE, September 23, 1943 the bar able ting at the rreater C1045 ompar- stating els istome steels mpering CONnvel showing the mos rdness in Fig charts, they the and 9440, the high (0.51), NE9440 lain ure 28. steel from ched the within the errors test, mention here. strength the reduction area resistance impact, shown Figure what designated the lower hardness range the sulphurized steels have satisfactory values. what designated the upper hardness range, Rockwell the sui- phurized carbon steels, while not hav- ing high values the alloy steels, are probably also satisfactory. How- ever, the hardness range above Rockwell these screw machine steels have definitely low values and designers should take this into sideration when their use above this hardness contemplated. Grain Size was stated earlier that grain size Was not important considera- tion for medium steels was the low grades. This statement should modified this extent, that the lower impact values steel treated produce coarse grain size not play such im- portant role lower hardness val- ues. Carburized steels are used well, whereas, medium carbon steels are used lower hardness levels Rockwell Should medium carbon steels heat treated hard- ness levels between Rockwell grain size the lower impact values obtained from coarse grained structures would become important. Quenching and Impact Some impact values for AISI C1137 steel, quenched from 1500 deg. 1700 deg. and tempered 500 deg. are given Figure 30. The effect the increasing quenching temperature produce increase the grain size and, therefore, lower impact values. Tensile values for AISI C1137 steel quenched from 1500 1700 deg. and tempered 900 deg. for given Table VI. The “P” value Was taken from report inves- tigation intensifying NE9440 steel, the Vanadium Corp. Amer- appears that the writer this article NE9440 steel considers about per cent the that the fine grained steel has value. 26—The rela- tionship tensile strength reduc- tion area. ASTM test bars, oil quenched and tem- pered 900 deg. used. TENSILE STRENGTH tempering perature ness five steels, oil quenched ‘rom 1550 deg. stand- ard round ASTM test bars used. ROCKWELL HARONESS 28—Relation- ship tensile strength Rockwell hardness. Stand- ard round ASTM test bars used. 240000 240000 a 200000 200000 UPPER HARDNESS | 80000 RANGE 1 80000 ABOUT 30-40 160000 160000 RANGE 100000 100000 10 20 30 40 50 60 70 REDUCTION AREA-PERCENT {37 | SPREAD DERIVED FROM ANALYSIS RANGE!| 35- 38)! 39155 COARSE 14 m 4 Zz m 600 700 800 900 1000 1100 275000 250000 225000 a 200000 — 175000 125000 GENERALLY ACCEPTED RELATIONSHIP BETWEEN 100000 75000 ROCKWELL HARDNESS 1700°F HEAT TREATMENT THE IRON AGE, September 23, | 10 10 TEMPERING TEMPERATURE STEEL CHEMICAL COMPOSITION AGS -1!050 5! 80 24 7 NE-9440 A2 48 12 7 i | STEEL CHEMICAL COMPOSITION . TENSILE STRENGTH m 2 m 1 80000 UPPER HARONESS 180000 z 3 RANGE o 4 vi 140000 LOWER HARDNESS 4 RANGE 20 30 ao 50 60 70 REDUCTION AREA-PERCENT QUENCHED OIL FROM INDICATED 500% LEFT 29—Relationship tensile strength reduction area seven steels oil quenched from 1550 deg. ard round ASTM test bars used. Area the right the vertical lines the chart indicates satisfactory believed that the user steel can, after considering the data given this article, come his own con- clusion whether the screw ma- chine steels can applied substi- tutes for alloy steel. seems the author that there are definite possi- 30—Effe bilities for substitution based in- timate knowledge the application particular part under considera- tion. The result such substitu- tion would conserve scarce alloys for more essent