The Iron Age 1943-09-30: Vol 152 Iss 14

PTEMBER 30, 1943 East d j j ¥ : \ TO\GET RESULTS! Army shower baths have colored tile, curtains, bath mats ...but they have everything the boys need keep clean! Whiting Victory Cranes are made without WHITING Whiting Victory Cranes are built accomplish re- sults. order get them work quickly, production time lost. Non-essentials are eliminated, construction methods streamlined, and readily available parts used wherever possible. Whiting Victory Cranes meet the exacting standards that have been reflected Whiting Crane performance for nearly sixty years. Soundly engineered, they are guaran- teed for long, reliable serv- ice the tasks for which they are designed. Whiting Corporation, 15601 Ave., Harvey, | THE IRON AGE, published every Thursday the CO. Entered second class matter November 1932, the Post Office Philadelphia under act March 1879. yearly North America and South America, Foreign $15, Vol. 152, No. 14. ELING CRANES 4 Office and Editer IRON AGE Vice-President General Advertising Offices 42nd St., New York Vol. 152, No. September 30, 1943 Johnson, Market Research Mgr. Baur, Typography and Editorial Business Surface Hardness RAYMOND KAY Los Angeles Inclusion Caused Casting Pit and Published Creep and Heat Resistant Steel CHILTON COMPANY Testing Wall Thickness Phosphatic Coatings Aid Plastic Electric Air Unit Speeds Stud Welding New Equipment—Welding Executive Offices Chestnut and Sts., OFFICERS AND DIRECTORS News and Markets Personals and Obituaries Non-Ferrous Metals News and Non-Ferrous Metals Prices; Scrap Iron and Steel Scrap News and Prices.................. Finished Iron and Steel Steel and Warehouse Semi-Finished Iron and Steel South America ond Pig Iron Prices 108 110 112 113 114 116 117 118 119 119 122 123 124 FOUNTAIN YOUTH FOR MACHINE AGE PONCE LEON came the New World seeking Fountain Youth for the human race. never found it. Medical science may yet. this same New World the machine has been de- veloped its maximum achievement. Mass produc- tion commodities with the highest standards precision the American hallmark. The world’s largest users the products made from machine tools, the American people whole only now realize what they are, their significance world war, and the peculiar difficulties involved their manufacture; namely, that while machine tools make mass produc- tion possible, they cannot, turn, mass-produced. They are our master tools. ~ ~ Refinishing Large Lathe Bed the Surface Grinder. Drawn the Simmons Plant Lili Rethi. Machine tools, too, span life, but for them engineers have created unique Fountain Youth... the Simmons plant for Engineered Rebuilding. Here machine tools all types, sizes and ages throw off their years, return work The treatment: dismantling the bare casting, all surfaces refinished either grinding, planing hand-scraping; all worn parts, such gears, bushings anid shafts, replaced with new; the machine then re-assembled along the same lines followed the original manufacturer and tested under power, SIMMONS MACHINE TOOL CORPORATION 1721 North Broadway, Albany SIMMONS Engineered REBUILDING 36—THE IRON AGE, September 30, 1943 IRON ESTABLISHED ° Sept. 30, 1943 President and Editor BAUR Vice-President and ° DIX Monager, Reader Service News, Markets JAMES Associate PHAIR MacDONALD BARMASEL Editorial Assistants SCHIEN WILLIAMS BUTTERS Regional News and Technical CAMPBELL Pittsburgh 428 Park POST Chicago 1134 Otis Washington National Press Bidg. BROWNE Washington National Press Bidg. LLOYD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward OSGOOD MURDOCK Francisco 1355 St. J Editorial Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston SHARP SANDERSON Toronto, Ont. Los Angeles JOHN McCUNE Birmingham ROY EDMONDS i St. 4 JAMES DOUGLAS Double Barreled Problem ALEABILITY, during the coming post-war years going largely determined the cost and price products the ultimate consumer. move per cent more goods than did our pre-war markets, and thus finance consumption and employment without going deeper and deeper into the hole national debt, will require drastic cost and price reduction consumer goods. the case people such yourselves, who are the metal work- ing industry and hence several steps removed from the ultimate con- sumer, will mean turning out superior machines, materials and equip- ment capable reducing the manufacturing costs those who buy your products. This course problem primarily for your research, engineering and design departments. Your merchandising problem, with need for overall cost reduction will equally acute. The cost distribution, which large percentage final cost the consumer must drastically re- duced. Distribution now large portion total cost and its ratio has increased with the progressive decrease direct production costs. the old days, before the factory system developed, cost good deal more make pair shoes, hunter’s rifle farm wagon than did sell them—probably three times much guess. Today the final consumer frequently pays three four times the actual factory cost the article that buys. This does not mean that price has in- creased, for has not; and fact the consumer’s dollar today will probably ten times farther buying manufactured products than would handicraft days. the ratio which has changed—the ratio between the manufacturing and the distribution elements cost. For years, when one spoke “cost reduction”, thought pro- duction costs. Experts and efficiency engineers have gone through our factories with fine tooth combs, improving processes and methods until the cost making things has been brought astonishingly low levels. Now the same process must applied merchandising and distribu- tion. This problem which must taken top management. Government cannot solve it. has demonstrated that fact very clearly those industries such coal and transportation, which Government regulation has attempted supplant the competitive situation regu- lation. practically all such instances, consumer costs have progres- sively risen. Private industry reduced production costs our factories developing mass production. accomplished this not reducing but increasing the investment mechanization, and making compre- hensive and extremely detailed studies reveal waste time, effort and motion. Undoubtedly distribution would profit similarly cost reduction gave similar attention. E 3 r 4 4 4 | 4 | ts 4 | } | | ; | e > 4 | Jimmy anxious see his Dad— his Mother working for Victory. Mother now head the crane hookers one the Inland departments. Jimmy’s Dad Fights, His Mother Works, Help Bring Victory Little Jimmy’s Dad, Sgt. James Maloney, doing his bit Air Force fighter squadron win this war. Jimmy’s mother doing her bit, too, head the crane hookers Inland Steel Co. department. Sergeant Maloney left Inland enlist Sep- tember, 1940. Jimmy was only about five months old when his Mother, also former Inland employe, re- turned work. She wanted her part, along with Sergeant Maloney, hasten the day when peace will return and Jimmy will see his Dad for the first time. Dearborn St. Detroit St. Paul St. This little family story typical the American spirit for spirit which moves men and women all their power help supply fight- ing equipment needed America’s fighting men crush the enemies Democracy. you know man, woman, not now war person who can take place industry left vacant fighter? so, urge him her join the ranks war workers and hasten the day when Jimmy’s Dad and all the other victorious Yanks will come marching home. Chicago Kansas City Cincinnati New York ~ BS a ERSA . News SEPT. 30, Private Congressional canvasses show that the universal conscription bill were come now, would likely pass the House votes. Meanwhile, the works general, national job freeze and labor priority directive, considered its authors alternative, many others ary conscription. Inter-agency disputes over contract termination have reached the point where termination control may vested entirely new procurement agency created through the Office War Mobilization. Dismissal wages for workers, analogous reserves for industry, one major termination policy not showing signs becoming tangle. Use hardenability characteristics instead chemical analyses for specifications coming commercial development steel. Several mills are experimenting with adjustment ladle additions hit hardenability limits instead analyses specifications, large warehouse supplying customers with Jominy tests results each lot alloy steel. Phosphate coatings, brittle under ordinary test conditions, have recently been shown capable developing the ductility and deformability necessary for parting layer separating the tool and the work during deep drawing. Army officials several times six months have threatened the Axis with the mighty punch America's new particularly the only little larger than the Fortress despite much rumor the contrary. The prototype now flying around one tough looking baby, but production prospects indicate that will many month before there are operational squadrons. Meanwhile: Experimental bombers much larger than the genuine air ships, will likely never have much role this war. Equipment orders are being filled here for four Russian blast furnaces, with Lend-Lease taking care the financial arrangements. Brass cartridge cases, the larger sizes, are still the preference the Army, despite the remarkably low failure record steel cases. Britain, which has rigidly adhered brass cases, has just placed heavy steel case orders this country, mostly the and mm. sizes. period history has witnessed many genuine new instruments warfare has the past several years. Radar one; new anti-submarine technique another; and still another very development reaching completion that itself could well win the war. And two more about which very much more will heard are bombs, and rocket equipment for aircraft and for bombs and shells. The Germans have long kicked overloaded bombers off small fields with supplementary rocket equipment attached the wings, and the Italians for over year have had airplane military size powered rocket energy. bombs were yanked from under the censorship blanket Churchill's disclosure week ago that the Germans are using them with effect. The development has roughly followed this pattern: First: Russia's Stormovik airplane for several years has carried rocket bombs slung wing rails, aiming being done aiming the airplane and the rocket energy employed solely give added penetration knock out tanks. Second: year ago the U.S. came out with much smaller variation, the Bazooka, infantry weapon for stopping tanks. About the same time the Germans unsuccessfully with very heavy rocket bombs the Stormovik pattern against naval the Mediterranean theatre. Third: The next logical step was increase range and accuracy rocket bombs radio actuation vanes the bombs. The Germans are already doing this with quite heavy bombs, dropped groups some miles away and miles from the The whole operation pretty tricky, but promising that will receive great deal attention over the next year. ‘ q punch and form block used the hydro-press ex- cellent method for sheet metal parts. However, certain prob- lems arise when this method used that require special attention the part the designer order pro- duce satisfactory finished part. The most serious problem that form- ing flange about convex radius. When flange formed about convex radius, the metal com- pressed since the outer edges the blank are forced into smaller diameter. The extent the compres- sion determined the width Section A-A dro-press form block. this type flange relief, the cutouts are within the normal mold line the form block. Hydro-Press Forming the flange, the angle bend, and the convex radius. Due the inability the rubber punch force the metal flow compression and hence thicken, buckles will form the flange and must made smooth hand operation unless some form relief provided. Two widely used methods for flange relief are notching and scalloping the edges the blank. Both these methods require extra time and care material preparation and should therefore not con- sidered. Flange wrinkles always bend away from the forming die due the fact that the forming dies does not allow 2—Use tapered notches the form blank work well enough form blocks having ra- dius in. over, but not pre- vent outward buckles when radius small in., these pho- tographs prove. IG. 4—Use Masonite dam around the form block helps direct the rubber pressure against the flange be- ing formed. 40—THE IRON AGE, September 30, 1943 the metal bend inward. Therefore, seemed logical presume that forming block designed allow the flange buckle inward duce smooth faying surface ex- cept where the inward wrinkle occurs. The successful forming inward flange wrinkles hydro-press opera- tions during production will eliminate approximately per cent the time required produce the average part that leaves the hydro- press the present with uncontrolled outward wrinkles. The Division North American Aviation, Inc. eliminated the necessity for hand work after . n n d ore, the pro- ex- era- will cent the orth ated ifter convex radius, buckles wrinkles generally occur that ordinarily must removed hand operation. This report summarizes the results experiments made overcome this handicap relieving the form block produce inward buckles and leave smooth faying surface suitable for riveting. forming fuselage frames the notch the form block allowing the metal buckle inward where the notches occurred. This provides smooth faying surface between the in- ward wrinkles, but this method worked successfully only for convex radii in. over. The value this type flange relief, however, was realized the Inglewood Divi- sion and experiments were made determine method for relieving flanges formed the hydro-press around smaller radius. Experiments were initiated using masonite form blocks having 4-in. convex radius. The 4-in. radius was judged practical minimum radius for experimental purposes previous experience indicated that radii between and in. produced the more serious flange wrinkles. standard in. flange depth was used order reproduce prevailing de- sign practice North American Aviation, Inc. The first experiment was made with form block having tapered cut- outs in. centers, Fig. The material used was 0.032 in. Alclad. Results were very unsatisfac- tory, shown Fig. There were indications that the inward wrinkle started only four places. Addi- tional cutouts were added give spacing in. centers. The ad- ditional cutout produced slightly better condition but the resulting part still contained outward buckles. Use Dam Cutouts the form block were revised removing the taper the cutout and running the radius the BELOW 5—Cerrobend wedges conjunc- tion with Masonite dam give full control flange wrinkles. (See also Fig. 6.) Cerrobend notch inside the normal mold line Parts produced revised block were not entirely satisfactory, but the metal had started buckle the cutout locations which was in- dication satisfactory progress. From observation the metal part, was apparent that the rubber was creeping under the edge the flange, and preventing smooth surface from being formed between cutouts. Closer control the space between the edge the flange and the form block was accomplished building dam, Fig. ABOVE Uniform inward flange buckles are assured with Cerrobend wedges used con- junction with Ma- sonite dam. ° ° RIGHT 7—The out- ward buckles this fuel tank frame will have re- moved hammer- ing and shrinking. WILLIAM SNOW Engineer, North American Aviation, Inc. Inglewood, Cal. ° ° ° restrain the rubber and confine definite area where even pressure would exerted about the radius curvature well pre- venting the rubber from creeping un- der the edge the metal blank dur- ing the forming operation. Using form block 4-in. con- vex radius conjunction with the dam and flange in. deep, the fay- ing surfaces between the buckles were smooth enough accepted the inspection department, since the slight waviness left the flange edges would removed the rivet THE IRON AGE, September 30, gun during the riveting operation. Two hits the hydro-press removed most the remaining small waves the edge the flange. The material worked was 0.040 in. 24S0 alclad. The use wedges made Cerro- bend metal modified Woods metal that liquifies 160 deg. F.) was even more successful and produced perfect parts. make the wedges, Fig. metal blank was formed hand over the forming block and Cerrobend metal poured into the space between the part and the dam. After the metal had solidified, was removed from the forming die and cut into three separate slugs pro- vide for self adjustment during the forming operation. blank was put the forming block and hit once with the hydro- press rubber punch, then the Cerro- bend slugs were put place and the part hit once more with the rubber perfect part was produced. This operation was repeated several times and each case part was produced that required subsequent hand forming. Fig. shows one the slugs place and the quality the wrinkles formed. forming 0.040 in. 24S0 around in. convex radius, the addition part shown Fig. but formed block provided with cutouts. the wrinkles are inward. dam confine the rubber was all that was required form perfect part with one stroke the hydro- press. tank frame showing the outwardly wrinkled condition the flange when formed over die having provision for flange relief. The wrinkles are subsequently removed hand op- eration and then put the shrinker bring the angle bend back the approximate correct angle. Fig. shows the same tank frame formed over die having flange relief cutouts and dam confine the rubber. The results these first experi- ments indicate that further investi- gation from more technical view- point warranted, the relieving compression the flanges al- lowing the metal buckle inward entirely practical from standpoint. Desulphurizing with Acid Slags OME recent supplementary work the desulphurization pig iron with acid blast furnace slags, de- the Archiv fiir das Eisenhiitten- wesen, indicates that the strong de- sulphurizating action acid slags high temperatures (1700 deg. C., 3092 deg. F.) due only small part the silicon suphide liberated gas. The initially acid slags only begin exercise powerful desulphurizing action the pig iron when the latter has picked very high nically unsupportable amounts Si, over per cent, that the final slags are very strongly basic. The bulk the sulphur, actually more than per cent the total present, retained this highly basic final slag after the pig iron desulphur- ized. Lengthening the’ time reac- tion causes increase pig Si, thus 42—THE IRON AGE, September 30, 1943 raising the degree the slag and giving very low value for the pig iron. The proportion removed volatilization, which may amount per cent the total present, very small compared that taken the final slag, which can reduce the from 0.6 0.01 per cent. Changes the amount slag pres- ent are strongly reflected the content the pig iron when using slag, desulphurization being much less, less slag present; but reduction raises the basicity the slag much more with small amount slag than with large amount, that the gross effect may masked. Additions oxide the acid slags have less effect the high tem- peratures question than fluxes, but cause marked increase the amount the iron, which must re- duced, and correspondingly greater increase the basicity the slag; this necessarily results improved desulphurization the pig the high temperatures ruling, only small amount the oxide added remains the slag, also only little the passes into the iron, the bulk being probably deposited carbide the walls the graphite crucible. From these experimental results the authors deduce the general condition governing the desulphuriza- tion pig iron with blast furnace slags, particularly the effect the basicity the slag, the content the pig iron, and the amount slag. comparison the results laboratory experiments with actual desulphurization the blast furnace indicates that there numerical cor- respondence between the two reac- tions and the governing conditions. Intensity reflected > W 1s cl ul m al Oo! ater lag; ittle the riza- nace the Surface Hardness ness thin layers, particularly brittle materials, have met with little success, owing largely the fact that very small indentation difficult produce under standard conditions and difficult measure ac- curately. Also, the properties the underlying material may exert pro- found influence the result. The methods which such measurements are now made are not regarded entirely satisfactory, and for certain purposes they are completely value- less. These cases include the very hard electroplated white bronze coat- ings, and the surfaces metals that have been polished, anodized, The hardness test has been used some extent for this purpose, but for very hard very thin coatings this not all satisfactory. new method for determining sur- face hardness, recently devised the laboratories the Tin Research In- stitute and described its publication No. 108, Bruce Chalmers, based the principle that while dif- TTEMPTS measure the hard- highly useful new method for measuring the hardness thin layers metals, involving reduction optical reflectivity after sand impact, described herein detail., addition, hard- ness values, determined the new method, are given for Weight sand, gm. 100 number platings and protective surface preparations. ficult apply very small indenting under accurately standardized very large number such forces that while each not under control, the result statistically definite. The procedure drop large number grains sand, particles emery, from fixed height the specimen. The particles are varying shapes, and, within limits fixed the screening the sand, varying size. They are, addi- tion, randomly orientated when they hit the surface. The impressions the surface therefore vary widely shape and size, but sufficiently large number particles used, the average shape and size the pits for measuring hardness sand indentations, shown diagrammatically. The specimen can moved either thé two positions and each which definitely located three balls the sole-plate which engage three six holes the base- plate the position the specimen under the end the tube length about in., the top which attached funnel. The required quantity sand placed the funnel, and, after striking the specimen, the sand deflected the baffle into the container The position that which the measurement re- flectivity made. 6-volt headlamp bulb en- closed suitable housing, projects converging beam light such way that the image the center the ellipse that affected the sand. The specularly reflected light collimated the lens measured means galvanometer. LEFT Variation reflectivity with Intensity reflected light 2000 quantity sand Upper scale used. 3000 4000 Weight sand, qm. depend only the hardness the material, while the number inden- tations depends the amount sand used. The average size the indenta- tions measured determining the reduction the specular reflectivity the surface. The instrument used, its simplest form, illustrated Fig. The variation reflectivity with the quantity sand used il- lustrated Fig. Experiments show that the graph obtained in- dependent the unit quantity sand chosen. found that the reflectivity approaches value the amount sand in- creased, this value differing for dif- ferent materials. THE IRON AGE, September 30, ig. its ri- ti- w- ng al- ion 3005 | } | ° ° ° | | | o ~ a * ° a w 3—Appearance different surfaces after the same amount sand action. the upper left the surface cast speculum metal, the upper right the surface brass, and the lower left the surface tinplate. action gm. sand. Enlarged 500 diameters. the sand used, enlarged diameters. TABLE Surface Hardness Some Hot Dipped Tin Alloy Coatings Surface Addition Hardness 1.0 per cent 0.1 percent 0.1 0.6 per cent copper............ 44—THE IRON AGE, September 30, 1943 TABLE Hardness Values Silver and Nickel All three were subjected the lower right sample Surfaces Protected Rhodium Plating Flash Composition Surface Hardness 300 165 TABLE Hardness Values Selection Protective Oxide Films Surface Surface Hardness Kerr’s protective Black film, 240 Black film, 170 Aluminum TABLE Effect Surface Preparation the Surface Hardness Annealed Method Surface Preparation Hardness Ratio Anodically 1.0 Polished with 1.9 Polished with “Brasso”. Polished with mop and 130 3.7 The appearance different sur- faces after the same amount sand action shown Fig. Among the surface hardness mea- surements made the Tin Research Institute were series hot dipped tin alloy coatings, silver and nickel sur- faces protected flash rhodium plating, and certain oxide films. Val- ues for these measurements are given Table summarizes the effect surface preparation the surface hardness annealed copper, while Tables and summarize data for tin and nickel. Some preliminary measurements were made ascertain the effect heat treatments the hardness the surface layer. The results far obtained show that the increased sur- face hardness tin due polishing burnishing retained after an- nealing 212 deg. for several hours, while the increase Vickers hardness produced rolling re- moved less than half hour under similar conditions. Results copper, however, have shown that most the extra hardness due polishing the mop removed annealing. This probably due the production worked layer under the Beilby lay- er; the worked layer softened annealing while the Beilby layer not. Cathodic treatment sodium car- bonate solution has been found reduce the surface hardness consid- h m re cc m ay 21 Nickel and rnodium........... at and reh tin sur- ium iven face ents far sur- veral ckers re- inder pper, the the This lay- TABLE Effect Surface Preparation the Surface Hardness Tin Method Surface Preparation Hardness Ratio Polished with mop and TABLE Effect Surface Preparation Surface Hardness Nickel Surface Bath anodically Bath 210 Inclusions Caused Casting Pit AILURE high percentage forgings meet transverse elon- gations requirements was thought due increase the non-me- tallic inclusions the slaggy stringer type, Rait reports the Trans- actions British Society. Since the occurrence this failure coincident with the use more siliceous refractories for uphill cast- ing, systematic investigation up- hill casting pit refractories source non-metallic inclusions was made and the following conclusions reached. The manganese liquid steel re- duces the free silica, particularly the quartz the refractory, produce MnO and silicon order reach equilibrium since the manganese-sili- con ratio the steel greater than necessary for equilibrium. The manganese oxide thus formed fluxes the refractory form liquid man- slag. The amount slag formed the more siliceous refractories considerably greater than the aluminous refrac- tories, the difference attack being attributed the large quartz content the former type and the very low erably. Some results illustrating this are given Table VII. Subsequent exposure air causes gradual in- crease the surface hardness, which does not, however, return the value measured before the treatment. Storage atmosphere nitrogen found suppress the recovery surface hardness. Less practical importance but great- academic interest attaches the use this method for studying sur- face phenomena, which one exam- ple the effect mechanical polish- ing the hardness the surface. The effect heat treatment the polished layer may also some interest, particularly when the metal concerned alloy subject age- hardening, temper-hardening, pre- cipitation. possible that the equilibrium such alloys may differ according whether not they con- stitute polished layer, since ap- pears that polished layer stable under conditions which the metal bulk, worked the same hardness, would anneal recrystallize. This may have some application con- nection with bearing surfaces that are subjected continued friction. content absence quartz the latter. The manganese alumino-silicate washed off the runner bricks and car- ried into the ingots. the case small ingots, freezing suffi- ciently rapid trap some this slag. During forming, which are plastic are formed into stringers. the case forgings steel poured through the siliceous re- fractories there are enough stringers lower the transverse elongation. The composition and amounts slag formed given type re- fractory different alloy steels with similar carbon, manganese and sili- con contents are very similar; thus the alloying. constitutents have little with higher manganese content and manganese-silicon ratio produces slag with higher MnO content given refractory. The composition the slaggy inclusions therefore con- trolled the carbon, managnese and silicon contents the steel and the composition the refractories. The extent which crystallization these TABLE Effect Cathodic Cleaning Surface Hardness Surface Hardness Metal Before After Cathodic Cathodic Treatment Treatment 200 2\as 540 225 110 White bronze: 740 132 120 Refractories slags completed governed the subsequent heat treatment the in- gots. Another important factor the formation these inclusions the constitution and properties the re- fractories. The manganese attack greatly reduced when quartz ab- sent, which normally requires mini- mum alumina content per cent. Fireclay refractories should fired minimum temperature about 2010 deg. attain the minimum free silica content. The maximum the spalling resistance-firing tempera- ture curve should occur 2010 deg. higher that the maximum adequate spalling resistance can achieved with the minimum free silica content. has been found various steel works that fireclay nozzles which have been boiled tar have increased resistance wear. The most prob- able explanation that the free car- bon deposited the pores the nozzle decreases the manganese re- duction silica and the evaporation the volatile fractions the tar tends maintain the nozzle lower temperature. THE IRON AGE, September 30, i tio er 1S car- nsid- Applied Ship Construction standard welding practice, penetration the root the weld can expected without special plate edge preparation, and the conventional practice filling grooves and building heavy reinforcements wasteful time and material. Experience with the deep fillet technique used this yard shows that the savings labor and material lie the range per cent for work which the technique specifically applicable. the present time this process limited continuous fillet welds the flat and horizontal positions. neering department the Cali- fornia Shipbuilding Corp. em- barked program testing and development based the findings the Lincoln Electric Co., Cleveland, and reported its bulletin No. 432, Welding Technique for Speeding War Production,” Septem- ber 1942.* avoid the use trade names and cover minor variations October 1942 the welding engi- *See also “Faster Arc Welding With Less Electroded Material,’ Iron Ace, April 30, 1942, describing the Lin- Fleet-Fillet technique. Several other welding equipment suppliers had independently developed similar processes and now practically all are recom- mending where applicable. the procedure, the California Ship- building Corp. refers this technique “Deep Fillet,” name derived from the unusual penetration obtained. The development program covering the application deep fillet welding consisted three steps: The accumulation physical data procedures The application these proced- ures quantity production. The first two parts this program to proposed procedure and policy relating certain phases the third 46—THE IRON AGE, September 30, 1943 part, have already been covered previous article the same authors, entitled “Deep Fillet Welding Tech- nique and Application,” published The Welding Journal, June, brief, the three fundamental features this technique are: The proper welding current must selected, which measured for the sake convenience and accuracy terms the amount time (burn off rate inches per minute). The proper off rates for each design size weld are given Table The proper length and elec- trode angle are essential. short are required and best results are obtained lightly dragging the electrode with the coating contact with the two plates all times. The proper electrode angles flat and hori- zontal position work are shown Table high travel rate essential obtain the desired savings time and material. other fea- tures the technique are ad- hered to, the strength the weld will independent its gage size and the welding speed, pro- vided good appearance and free- dom from holes, cracks and un- dercut are maintained. the high travel rate, less mate- MacKUSICK Welding Engineer HIATT Mechanical Engineer ANDERSON Engineer charge Testing Laboratory California Shipbuilding Corp., Terminal Island, Cal. ° ° ° rial will deposited per unit length weld and the saving welding time obvious. Recommended travel speeds in. per min. for flat posi- tion and in. per min. for the hori- zontal position have been established effort secure uniform results and the same time take advantage reasonable savings time and materials. The use watch other timing device check welding speeds the job impractical, and after oper- ator has developed reasonable facility with the technique, timing travel speed unnecessary. close check can maintained welding speed using the data Table II, which shows the length weld deposit that will obtained the proper current and recommended travel speeds are used. The use clip-on type ammeters offers quick check welding cur- rents. This type meter overcomes the disadvantage meters directly connected the welding generator that less subject shock and abuse, and using the same meter for large group machines any variation between meters obviated. Furthermore can readily cali- brated daily. should noted that different electrodes require different currents consume the same amount electrode per unit time. Hence table currents and burn off rates desirable for use with the meter. alternative procedure recali- brate the scale the meter read directly burn-off rate for any elec- trode group electrodes. Immediately upon completion the Deep Fillet Welding | gth ing Osi- ori- hed ults age and the per- avel neck hich that rent are cur- ectly and 1eter any ated. cali- that ount rates eter. cali- read elec- the development work the laboratory, steps were taken put this technique into operation. Since only few the 7500 welding operators this yard had had any connection with the proposed procedure, the first step the application production was training and certification program for electrodes and operators. the ab- sence any approved qualification procedure the American Bureau Shipping the American Welding Society specifically applicable fillet welds, the following procedures for qualification electrodes and oper- ators were drawn the welding engineering department and approved locally representatives the American Bureau Shipping and the United States Maritime Commission. These procedures have subsequently been approved David Arnott, chief surveyor the American Bureau Shipping, cover qualifications the California Shipbuilding Corp. only. Qualification Welding Electrode cross welded specimen using in. plate with four fillet welds in. nominal fillet size shall made using Fleetweld No. 11% in. rod for two fillet welds one side the specimen. Welding technique shall accordance with approved Fleet Fillet proced- ure. (Burn off rate-of 11% in. per min.) The welding rod quali- fied shall used make the two fillet welds the opposite side the specimen using exactly the same welding technique used for the two Fleetweld No. fillet welds. The two fillet welds made with the rod qualified shall made cold material; heat from other welding shall exist the sample. “Two tensile samples and one etched sample shall cut from the specimen—samples least in. length. Average tensile strength shall least equal that strength given for Fleet Fillet in. nominal size weld (28,100 Ib. per lineal in.). Etched samples shall show proper penetra- tion and appearance struc- ture.” Qualification Welding Operators For Deep Fillet operators shall certi- fied use the deep fillet welding technique (Lincoln Electric Co.’s Fleet Fillet technique) follows: “Welding operators shall given instructions technique deep fillet welding competent instruc- tors and shall deposit sample deep fillet weld pre- determined size. Weld sample shall macro-etched cross section and weld must measure with least the penetration that quired for selected size weld. The appearance the weld deposit must sound and free from de- fects. “Qualified welders shall fur- nished with qualification cards signed the testing engineer show- ing name and badge number and indicating that has been tested and qualified for deep fillet welding technique.” will noted that Fleetweld No. electrode manufactured the Lincoln Electric Co. was selected comparative standard. This selec- floors deep fillet welded the top tank inner bottom section. tion was made because the Lincoln company had already secured tenta- tive A.B.S. approval this electrode for use with the Fleet Fillet welding technique. The American Bureau Shipping has suggested the use conventional fillets for comparative purposes, but the data available com- paring the relative strength deep fillet welds made with Fleetweld No. and other American Welding So- ciety Type 6030 electrodes and con- ventional fillets extensive that there very little difference between standards. The American Bureau Shipping has made the choice standards optional with the California Shipbuilding Corp. TABLE Procedure for Deep Fillet Welding Position, Using AWS E-6030 All-Mineral Coated Electrodes Flat Horizontal Recommended Travel Speed In. per Min. Electrode In. Flat Horizontal per Min. | | THE IRON AGE, September 30, 1943—47 date different brands elec- trodes the AWS 6020 and 6030 classifications have been tested under the above qualification proced- ure and approved the local sur- veyor the American Bureau Shipping for deep fillet welding this yard. These brands cover most the principal manufacturers welding electrodes the United States. Training Operators Nearly 2000 welding operators have been instructed and tested under the conditions outlined the paragraph qualification welding operators. The policy instruction has been give short discussion the prin- cipal features the technique small group men followed demonstration where each individual can try his hand. After running two three electrodes the average oper- ator quite capable making acceptable test plate. However, unless the operator unusually attentive and interested usually necessary give additional instruction the job. has been the policy the production departments this yard have instructors closely supervise the work all deep fillet crews. These instructors keep careful watch the electrode burn-off each man and correct electrode angle and see that proper arc length maintained. This instruction makes much easier show man the re- sults his errors and give addi- tional information handling cra- ters, weld failures, undercut, etc. The most common tendency for the operator hold too long the usual result which serious un- dercutting. The present policy this company Forward deep tank flat welded with deep fillet welding tech- nique and (below) detail typical weld include instruction flat and horizontal fillet welding using both conventional technique and deep fillet technique part the regular course instruction its training school. identification card issued all deep fillet operators showing the operator’s name, badge number, and the positions which qualified. The reverse this card (see Table shows the proper electrode angles, speed and burn-off rate for the most common applications for handy refer- ence. Application Gradual The application these procedures production welding has been gradual one. general, the proced- ure has been select first those sec- tions with the greatest amount flat horizontal position work, which are welded with continuous fillet welds. When subassembly has been selected for welding with the deep fillet technique, letter sent the company inspectors, the A.B.S. local surveyors, and the Maritime Commission inspectors, notifying each group the change welding pro- cedure and the hull which the change will effective. This infor- mation must also turned over all groups concerned with the inspec- tion and mark-up unsatisfactory welding that these welds will not marked built gage size after the subassembly shipways. addition, representa- tives the American Bureau Shipping and the Maritime Commission are present each new subassembly section welded for the first time. They deserve great deal credit for the helpful consideration they have shown during the stages application this technique. The plate shop handles nearly all welding positioners and has been able adopt the technique much more readily than other welding groups this yard. This because the shop uses smaller group welders, all whom have had more experience the use large elec- trodes the type used with this technique. addition, work the flat position has less operating diffi- culties than that the horizontal position. The plate shop welders were able few weeks convert nearly 100 per cent their flat zontal position continuous fillet weld- ing use the deep fillet technique. The only exceptions have been few subassemblies such size and rigid- ity that they not lend themselves fabrication with the technique, will noted later. The adoption these procedures « ‘ A A 3 flat are llet een eep the ime ach the for- not size the nta- new the deal tion all has ding ause nore elec- this the diffi- were hori-, veld- ique. few igid- ures the subassemblies division has been somewhat slower process. This has been due larger group personnel trained and more cautious approach, prompted the greater technical difficulties encoun- tered while welding position. this time, nearly all the flat and horizontal position con- tinuous fillet welds are made using this technique both the shop and the assembly skids. This repre- sents about 16,000 ft. daily pro- duction welding approximately per cent the production these two departments. large portion the remaining work performed these departments increment weld- ing which has not yet been changed over because the problem filling Figs. show examples the deep fillet welding now duced this yard and the conditions under which they are being made. Studies made random show that actual savings more than per cent time and per cent elec- trode consumption can realized using this technique. For example, small bulkhead section where channel and H-section stiffeners are continuously welded, the following figures were obtained 1365 ft. Fig. 3—Typical bulkhead welded using deep fillet welding technique. This figure should compared with the daily average about ft. for all welders the same department. While the savings illustrated above are considerable, they are 5/16 in. horizontal fillet welds: means the ultimate. the welding Conventional Deep Per cent Technique Fillet Savings Saving Pounds Electrode 459.5 292.5 25.5 one the larger inner bottom sections, weighing 34% conventional technique used weld- ing the vertical floors the tank top, was replaced deep fillet. this section, 1335 ft. 5-16 and in. horizontal fillet welding was changed the deep fillet technique. The fol- lowing savings were realized: operators develop more skill, savings manhours and electrodes should approach per cent for conditions where this technique applicable. A.C. Preferred Deep fillet welds made with alter- strength welds made under the Conventional Deep Per cent Technique Fillet Savings Saving One welding operator has same conditions burn-off rate with known produce 290 ft. sound 5/16 in. horizontal fillet weld 8-hr. shift. While this excep- tional case, indicative the ultimate result which can attained. direct current. For this reason and because the elimination mag- netic blow, the use alternating current preferred direct current, although either type equipment will produce satisfactory results. selecting machines for either alternating direct current should remembered that the required cur- rents will from per cent greater than those normally used produce the same size weld using con- ventional technique with one more passes. have found that machine 300-amp. rated capacity will satisfactory for and 5/16 in. deep fillet welds, but this equip- ment will probably not produce satis- factory deep fillet welds for the in. size. There may exceptions this statement the operating factor the equipment low the overload capacity the particular machine high; however, for machines which are operated 168 hr. per week operating factor per cent greater, machine 400-amp. capacity recommended for deep fillet welds. Electrode holders should selected the same basis the machines. Holders 300 amp. nominal capacity, when carrying 250 275 amp. high operating factor, become hot that operators cannot hold them even with heavy gloves. For all deep fillet welding, with electrodes in. diameter greater, 500-amp. holders holders with forced ventilation are recommended. Care must taken with ground connections see that they are made secure and with sufficient area contact carry the heavy currents without excessive heating. Ground bus made steel strap THE IRON AGE, September 30, / th A f ° ° avoided unless known that the current carrying capacity sufficient prevent heavy power loss. When ground connections are welded into place, the cross-sectional area the weld metal must equal the cross- sectional area the steel strap. Major Production Difficulties The work development this technique and the experience gained the training operators indicated that welds made following these es- tablished procedures were particular- susceptible the common problems all welding. The problems elimi- nating cracks, holes, and undercut and maintaining distortion within allowable limits are occuring. Fortunately, however, most the causes these difficulties are known even though the mechanism the failures may not known. general has been found that most the unsatisfactory welding can traced the welding operator who has been lax conforming procedures. Many welding operators. particularly those who have been welding for year less and whose training has not been well founded, fail recognize the advantages the drag technique. The feeling seems exist with majority old time operators that weld cannot made unless the electrode oscillated. These conditions emphasize the im- % & 4—Side view setup for fillet weld contraction test, showing location deForest scratch strain gages. training and adequate and informed supervision. More will said later about the causes and cures, but significant note that adherence procedure the most important fac- tor the elimination unsound deep fillet welds. TABLE Length Weld Deposit When Operating Proper Travel Speed With Proper Electrode Burn-Off In. Weld Deposited IRON AGE, September 30, Electrode With Proper Current and Design Electrode Electrode Burn-Off Recommended Speed Fillet Size Size Rate Leaving in. Stub POSITION HORIZONTAL POSITION Considering the more important problems detail, the most common and most easily corrected fault horizontal fillets undercutting the vertical plate. almost all cases this condition results from incorrect technique although undercut often ac- companies other conditions unsat- isfactory welding caused damp coating coating not specifica- tions. was found early our in- vestigations that electrode angle deg. the vertical essential prevent undercut even though greater angle might seem more de- sirable increase penetration. Sec- ondly, the high heats used with this technique, the shortest possible arc necessary for control. This means that drag technique with continuous contact between the elec- trode coating and both plates essen- tial. When the condition the coat- ing the cause undercut usually the result inadequate arc stabilization accompanied proper slag coverage. The presence blow holes the finished weld fortunately not com- mon. During our early investigations considerable difficulty enced with this condition but since the application these techniques production welding, cases this con- dition have rarely been reported. has been noted that certain brands electrodes are more susceptible the formation blow holes than others. Again this condition may related the moisture content the elec- trode coating. second cause blow holes has been found improper grounding the work. The formation cracks far the most important condition affect- ing the production sound welds using the deep fillet technique. These form temperatures the blue brittle range and are always longitudinal the weld. the cross- section the cracks start the surface approximately the center the weld and tend curve off into the plate (usually the vertical). root cracks transverse cracks have been 5—End view setup shown Fig. encountered over 3000 specimens. Once weld has cooled through the blue brittle range without the forma- tion cracks, failure has occurred result subsequent welding operations the side the loading the within the limits the designed stress range. When cracks were attributed high sul- fur content because the similarity the failure failures encountered Unionmelt welding known particularly susceptible sulfur cracks, and the similarity the tech- niques that Unionmelt. This theory not well substantiated analysis plate material, and sulfur now considered only con- tributing factor weld failures. Evidence tends favor the theory that the cracks are stress failures the blue brittle range caused combination stresses introduced into members the fitting proced- ures and welding stresses inherent the welding process. This condition residual welding stresses which result from the un