The Iron Age 1943-10-07: Vol 152 Iss 15

STEEL CO. oe Wherever you use metal that must withstand heat-treating temperatures, our Alloy 502 vites your consideration. the 35-15 type, and made cast form rolled rod and work from your own designs, offer our own suggestions. Many problems like this have come our way, and they have taught considerable that, course, we're glad pass you—if you need. know the metal, Alloy 502, and think we've learned where and how apply it. So, you're thinking about heat-resisting alloys, write us. also make electric furnaces for such pot and box types. Also, Hoskins Brazing Furnaces are fast and compact. Described Catalog Hoskins Manufacturing Company, Detroit, Michigan. ELECTRIC HEAT TREATING FURNACES HEATING ELEMENT THERMOCOUPLE AND FIXTURES SPARK PLUG ELECTRODE WIRE SPECIAL ALLOYS NICKEL PROTECTION TUBES THE IRON published every Thursday the CHIL (INC.). Entered second class matter November 1932, the Post hiladelphia under act March 1879. America and South America, Foreign $15. Vol. 152, No. 15. Pos General Editorial and Advertising Johnson, Market Research Baur, Typography and President and Edite: BAUR Business Managers New York New York 100 East 42nd St. 100 East 42nd BLAIR Pittsburgh Guardian Bidg. 428 Park Chicago PEIRCE LEWIS WARREN RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and CHILTON COMPANY Execative Offices Chestnut and Sts., Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, HILDRETH GEORGE GRIFFITHS SVERIT TERHUNE BAUR WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary MARRY DUFFY CHARLES Vice-President Member, Audit Bureau Member, Business America, America and Address, The IRON AGE Vol. 152, No. Editorial Taking the Cent from Incentive ° ° ° Technical Articles Torsion Impact Properties Meehanite Aluminum Casting Alloy Substitution Engraving for the Aircraft Effect Forging Bending-Fatigue Strength Automatic Helium-Shielded Arc Production Short Creep and Heat Resistant Steel Castings Time Saving Core Report Iron and Steel Engineers Concrete Strengthens Welded Steel Base New Equipment—Machine Tools ° ° Features News Front Assembly Line Washington West Fatigue Cracks Dear Editor News and Markets WPB Seeks Solve Flat Rolled Steel Supply Factors Indicate Need for Scrap Drive. Political Factor Rules Planning, Flanders Says Improvements Made ASU Redistribution Steel Shipments for August Personals and Obituaries Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Prices Steel and Warehouse Prices Stainless Steel, Tool Steel Prices Semi-Finished Iron and Steel Prices Pig Iron Prices Ore and Coke Prices Prices Index Advertisers October 1943 279 3 ° ° ° | 106 106 166 170 171 177 177 180 181 182 . ° ° Post Office 5. IRON AGE, October 1943 Wartime Emergency Steels Ryerson Stock AIRCRAFT Available through the ACW plan ALLOYS hand for all essential applications Write for helpful booklets Call Ryerson for the steel you need quickly, whether it’s day-to-day needs emergency or- ders. Your nearby Ryerson plant carries over 10,000 different kinds, shapes and sizes steels stock for immediate shipment. And, stocks are now adequate meet requirements. our Chicago, St. Louis, Cincinnati, and Jersey City plants, carry Aircraft Alloy bars 8630, X4130 and 4140 various condi- tions and wide range sizes. These spe- cial stocks are earmarked for aircraft use. They meet government specifications and are offered accordance with the ACW program. Ryerson Alloy Steels the carburizing, medium hardering and high hardening grades are available all ten plants wide range sizes. Ryerson furnishes helpful test data RYERSON SON, Plants at: Chicago, Milwaukee, St. Detroit, Cleveland, Cincinnati, Buffalo, Boston, Philadelphia, Jersey City RYERSON and physical property interpretations with each shipment Steels. Informative booklets helpful data have been prepared. The Aircraft Alloy Steels Booklet lists available steels stock; gives condensed version the AMS and ANS spec- ifications they pertain steel. The Booklet covers the explanation the Jominy Test and its relationship the physical prop- erties steel; lists available stocks; and pre- sents physical property information many popular Steels. Copies both books are yours for the asking. Make Ryerson your number one source for steels. Let our engineers and metallurgists work with you. Call Ryerson first for action steel. ff Hf | Mc | Ne : Te q Re IRON AGE ESTABLISHED 1855 ° Oct. 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 Regional News and Technical Editors CAMPBELL Pittsburgh 428 Park POST Chicago 1134 Otis MOFFETT Washington National Press BROWNE Washington National Press LLOYD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS Louis JAMES DOUGLAS Seattle Taking the Cent from Incentive HIS editorial directed you men and women our industry who are paid commission basis and you people who em- ploy them. Smoke coming from your houses and you had better grab the water buckets. you not get busy and something about you may find yourself position where you will not permitted receive pay commission compensation for 1943 that greater than that re- ceived paid the same individual 1942 1941. Stabilizer Byrnes reported working that line and about issue order. Stabilization fine-sounding and impressive word, but the act stabilization carried extreme another less pleasant word fits the picture better. That word strangulation. strangled per- son completely, finally and definitely stabilized forever. And the proposal regulate commissions basis past performance would pretty definitely strangle selling incentive and with our hopes for maintaining post-war employment. Object the proposed new gadget for the already overgadgeted stabilizing machine keep down purchasing power. one has yet proposed the bright idea cutting hourly wage rates piece rates for the same purpose and any politician who did would face outraged constituency. Yet this proposal “stabilize” commis- sions similar nature. not aimed stabilizing the rate commission but the total amount earned. Thus salesman working per cent rate who this year through working harder, longer better boosted his sales volume per cent would find his rate cut the stabilizing mandate per cent. But this not the half it. Commissions are usually paid earned, weekly, monthly quarterly basis. most cases the money earned has already been spent invested Government bonds. Thus salesman one any commission-paying occupation who unfortunate enough per cent ahead last year Oct. will either have take three months’ vacation else work during the last quarter for pay. doubly unfortunate being per cent ahead the “base” year will have either one these two things and also pay back quarter year’s earnings his company. estimated that fully per cent our merchandising and service transactions are kept going the commission idea whole part. Now that are the threshold releasing more and more materials non-war products, would silly and damaging thing take the cent out incentive. you agree with would well let your congressman know how you feel about it. 4 f | | | q q i q q q | 4 4 | 3 § | | Better Steels are Coming— from the Tests War Hour after hour, month after month, Inland metallurgists study not only the needs for this war steel, but also the requirements victorious America— the America that will turn again peace- time developments the crafts, and the sciences—new developments that will prove again that free peoples set the pace for others follow. Coming out the tests war are finer steels—steels that will set new standards safety and speed transportation. Steels that will help bring the newest advancements swift communications into most homes the land. Steels that will bring new conceptions beauty, convenience, com- fort, and utility—all prices that can afforded the average American. Yes, you can look forward the day when steel from Inland, now flowing 100 per cent into war products, will help build greater America. INLAND STEEL COMPANY Dearborn St., Chicago, Sales Offices: Milwaukee, Detroit, St. Paul, St. Louis, Kansas City dange switc imper mines attac car per big had J incre News Government figures set current unemployment 1,200,000. Generally accepted figure for "irreducible minimum unemployables" was 3,000,000. The bill restrict government office employment draft age will have little effect civilians, most the draft eligibles having been caught the Selective Service sieve. But apparently will the transfer hundreds young officers and enlisted men from War Navy Department jobs replaced older men. coming executive order will transfer all foreign food operations Crowley. Most the U.S. responsibility for war and relief food will carried out under foreign development with the U.S. giving not great quantities free food, but (a) guaranteed markets fair price, (b) know-how, and some farm machinery and seeds. Addresses German steel plant engineers and executives, which used the Ruhr, are now changing, rapidly increasing numbers, Prague and Vienna. Newest complaint against the USES referral (Buffalo) plan, now being extended Detroit, that since women will remain free agents, they will obtain the best jobs. Pointing this grouse the fact that during the past year, increase the Detroit area has been entirely due hiring women. Male figures, static for months, are now dropping slightly. Workers Cleveland Automatic Machine Co. are being other manufacturers during three months' Cleveland Automatic conversion program. They will seniority, vacation rights, etc. Land mines, used phenomenal profusion the Germans, have accounted for far larger Allied losses personnel and equipment than indicated official Pictures always show detection bayonet probing, which slow and dangerous, electrical means, which has been rendered useless recent German switch wooden and plastic mine casings. Rapid opening paths through mine fields, often some miles depth, has become imperative. The British now use large sectional tubular framework which can forward hundred yards so, plowing the ground and setting off the mines. Americans have devised large rolls canvas wire netting which are many small explosive charges. Powerful springs roll this canvas out some feet, the charges are set off and the mines are exploded. Turkey, neutral, has adopted tax unprecedented severity. provides for capital levy wealth and excess profits salaried private employes, important companies, business men and real estate owners, with forced labor for those liquidating their tax within month. newly devised, sand reflectivity method now making possible hardness measurements thin surface layers, will split many hair surface preparation surface hardness. Random studies California Shipbuilding Corp. show that deep fillet welding, compared with conventional welding, making savings per cent bulkhead section jobs and per cent large interbottom sections, with per cent saving electrodes both jobs. January the personnel gap between required and actual total personnel for the big eight West Coast airframe producers was approximately 1300. June the gap had passed 19,000. But: during the first seven months the year, per cent increase production was achieved with only per cent increase employment. Now intensive pressure worker recruiting campaign planned the San Francisco Bay area avoid threatened cancellation contracts. will the principal quarry. Boeing "exit interviews" for first half 1943 showed that per cent all were women, three-fourths which gave domestic and personal reasons leaving. Elsewhere the country women also continue drift from war jobs the home. q 4 | q { q | | q 4 § City | 4 3 Heat Treatment Effect the Torsion Impact ‘7 AS ABOVE specimen used for the torsional im- pact test. For specimens Series and the bars were cast shape core, and 2—Comparative tough- ness tough and brittle steels, quenched from 1450 deg. Note the indication tough- ness tempering such low temperatures 300 400 deg. F., which has little effect the hardness such steels. 3/32 in. machined off over chined from 0.75-in. cast fig- LEFT 200 300 400 500 Drawing temperature, deg. TABLE Samples Used Testing Effect Heat Treatment Torsion Impact Properties Meehanite “GA” (Alloyed) (Alloyed) Sample marked: Series Series Series Series TABLE Torque Terms Ft.-Lb. Energy Absorbed Meehanite Series Series Series “GM” “GM” “GA” | “GA” 6.0 6.3 1.8 3.2 2.8 7.3 2.7 4.0 5.4 6.9 10.2 54—THE IRON AGE, October 1943 torsion impact method testing has been valuable studies toughness carbon tool steels, where the torsion strength has been shown vary within wide limits both tough and brittle steels, and where Izod Charpy values showed little change result varying the tempering temperature. The object the investigation de- here determine the effect tempering, after oil quenching from 1550 deg. F., the torsional impact strength Meehanite metals. The test samples, shown Table were prepared and heat treated General Iron Works, Den- ver. The torsional impact tests were conducted the authors State College, Pennsylvania, all cases the metal was tapped from the cupola 2830 deg. and the bars were poured hot, but actual measurements were taken the pouring temperature. Series and the bars were cast shape core and poured end, through gate. The finish left the bars was 3/32 in., and this amount was machined off over the entire bar. With Series and the bars were machined from 0.75-in. cast figure bar, cast core and poured end through 5/16-in. gate. The standard specimen used for the torsional impact test illustrated Fig. The testing machine, standard model the Carpenter torsion impact machine, was cali- brated that the energy” was equal (R.P.M.)* 0.000492, and the energy” equal (R.P.M.)* 0.000494. Data carbon tool steels, show- ing the difference between tough and brittle steels, are illustrated Fig. The important feature the indica- tion toughness tempering such low temperatures 300 400 deg. F., which has little effect the hardness such steels. The torsion impact values should also compared with the approximate data for Izod values the same steels. Data carbon tool steel contain- ing small amounts silicon and mo- overs and diam perm been The are S & Torsion impact strength bars the The ing exac cord the Tabl unall ing denu corre 160 Properties ° ° LIPNICK, Pennsylvania State College, State College, Pa. ° ° lybdenum are given Fig. The graph shows the effect tempering 1000 deg. and correlates the torsional impact strength with the Rockwell hardness the tempered bars. After preheating 1550 deg. F., the test bars were quenched oil and withdrawn smoking 300 deg. The bars were then tempered for min. various temperatures, rang- ing from 400 deg. 1200 deg. The exact tempering temperatures are re- corded with the data obtained from the torsion impact tests, shown Table II. The results “GM” and “GA” show, comparatively, the effects tempering alloyed and unalloyed Meehanite, when cast oversize test bars (Series and and when cast straight %-in. diameter bars (Series and R). Plots these data the compari- son basis thus drawn are included permit ready analysis the results. Values Brinell hardness have also been added the chart Fig. The pletted data for Series and are included Fig. deg. carbon tool steel contain- ing small amounts silicon and molyb- denum. Torsional impact strength correlated with the Rockwell hardness the bars. hardness impact strength Torsion Drawing temperature hour temp.) wow w 200 300 400 500 600 700 800 900 1000 Rockwell hardness 200 600 800 temperature, 1200 4—Effects tempering torsion impact and Brinell hardness properties alloyed and unalloyed Meehanite, when cast oversize test bars (Series and B). 5—Effects tempering torsion impact and Brinell hardness properties alloyed and unalloyed Meehanite, when cast straight diam. bars (Series and cast + | Brinell har 230 dness Series Torsion impact, 600 800 Drawing temperature, deg.F 200 1200 THE IRON AGE, October — 350 -Machined off 330 e- Cc 8 4 | no ere ° ° red in., ars for End 9 | | | data eels. ain- cast mo- Aluminum Casting Alloy Substitution Approximate Equivalent Specifications for Aluminum Casting Alloys Army Commercial Federal Ordnance Navy Aeronautical SAE ASTM Sand Castings Specification QQ-A-601 AXS 784 46-A-1 (INT) Number Number 26-42 and (5-1-42) E-QQ-A-601 Alloy Class Class Class Alloy Sec. 355 and Sec. 195 AN-A-5 E-325 and Modifications AN-A-4 E-326 212 AN-QQ-A-399-2 CS21 Permanent Mold Castings Specification QQ-A-596 Number Number 108-41T (2-1-42) Alloy Class Class Alloy A132 AN-QQ-A-386-2 SN41 C132 Sec. 355 and Modifications A108 Die Castings Specification QQ-A-591 Number 46-A-14 (INT) Number Number 85-42 (2-1-42) AN-QQ-A-366-4 EA-B85 Alloy Class Class Class Alloy A379 AXS 679 E306 LXXIX-B 56—THE IRON AGE, October 1943 help improve the situation aluminum casting alloy materi- als, WPB’s Conservation Divi- sion has recently issued substitution chart and table approximate equivalent specifications. This chart divides into four groups, according the percentage pri- mary ingot scrap aluminum speci- fied, the standard aluminum alloy specifications used sand, permanent mold and die castings. will noted, specifications con- taining the highest purity ingot are the left, grading those with the most scrap the right. The ac- companying table equivalent speci- fication tables translates the commer- cial specifications into the approxi- mate equivalent government and en- gineering society specifications. using this chart, two things should remembered. First, satisfactory, less critical substitute material some other field can used, even the lower grades alu- minum should avoided. Second, high mechanical properties, specific physical properties, maximum resis- tance corrosion particular cast- ing characteristics inherent al- loy toward the left the chart are the war effort use alloy nearer the right. With respect special character- istics alloy No. 142 occupies unique position. Because its nickel con- tent, not desirable substitute for other alloys, while for certain high temperature uses suitable alter- nate materials are not available. should used only where its unique characteristics are essential. Because directives issued some the alloys column are available from the secondary smelters only limited quantities. tric’s difficul smooth hubs facing than employ hoy The wit The than turned made turn hen PERN | ' VIRGIN METAL TYPE CASTING Made entirely from Pure Primary From Made from Primary and /or High Purity Segregated Scrap 142 Cu 4-Mgi.5-Ni 2 Elev, Tema, Apptic, Only Cud-MgiS-m2 = ' Elev. Temp Apptic. Onty | if Made from Segregated Scrap with Required Pure Blending Secondary ALUMINUM CASTING ALLOYS SUBSTITUTION CHART CONSUMPTION SCRAP Made from Mixed and Obsolescent Scrap Secondary ! HEAT TREATABLE | NOT HEAT TREATABLE ! ( Alloys enclosed within line are susceptible to heat treatment; those within « time are not. ) Gu PERMANENT | 355 Modit Bis 195 Sec 6195 cus | 2n LB - Mg si5 Wu4.5-Si 45 - Cu -Fe Si \S-Zn2 } 8! Cu?-Si3 12 Special Spot-Facing Tool for Hub Nut Seats facing tool developed Fillippo, workman General Elec- Schenectady Works, overcomes difficulties encountered securing smooth seat for nuts and bolts split hubs rotor spiders. Using the spot- facing tool slightly more expensive than the chipping method formerly employed, but does superior job. Chipping left rough surface mat- how the cutter carefully was done. The holes the hub are inaccessi- ble with ordinary spot-facing tools. The tool devised Fillippo than the hole through the hub. the detail view, the shaft turned from 2%-in. bar stock. End made in. square for in., where plate fitted with two pins left. The balance the shaft turned in. diameter and Next, threaded the end. slotted top for the pins, slipped onto the shaft shaft thus assembled slipped through the hole the hub. bearing sleeve fit the and the inside diameter the hole put place, followed bearing cone The threaded end the shaft slotted with keyway hold washer and nut place, thus completing the assembly. applied Motive force with ratchet the square end the shaft while the fed into the seat means the cone, washer and nut. When one surface has been spot- faced, the assembly reversed fin- ish the opposite seat. <> THE IRON AGE, October INCREASING CONSUMPTION 6,5 - | 214 == 108 21 Gu4-Sil2 ri- en- ings itute ecific resis- cast- Engraving for the Aircraft NGRAVING may into the following three classes: Copying flat sheets from some form master; cutting away the metal leave the design re- lief, the case punches, dies and molds; and cutting away the metal roller-type dies leave the design relief, used for engraving rules, plastic molds, Fig. seen model CXL Taylor, Taylor Hobson machine set for engraving batch air- indicator dials. facilitate location guide clamped the worktable. Secured the copyholder situated the rear master copy (Fig. with the design cut into plastic sheet; this carefully drawn and engraved hand provide the had been larger brass master copy would have been used eliminate the effects wear caused the stylus moves around the design. For very large steel would employed. When making the master copy, care must taken observe the drawing limits which, for dividing, may within min. the depths graduations and figures can controlled within 0.001 in. this particular example, allow for luminous filling, the depth the engraving 0.012 in. The CXL engraving machine de- ELEVATION DEPRESSION 58—THE IRON AGE, October 1943 signed for handling larger work and bulkier articles than the other standard models the range. The pantograph can set reduce from enlarged copy any ratio sary, down With the ratio in. diameter can covered one setting. This feature being able cover such large area very useful when engraving scriptions from copy made loose characters, the case larger Another which provides maximum clearance in. between the cutter and work- table. The swan-neck design this RIGHT with plastic mas- ter copy set for engraving aircraft dials. BELOW plas- tic sheet master copies, together with the dials en- graved from them. machine makes possible engrave plates 19% in. width one setting the worktable. revers- ing the plate, widths in. may handled. Drive from motor at- tached the pedestal, the belt being carried the cutter spindle behind the machine and therefore well away from the operator. This same motor can also used drive cutter machine which may fitted attachment. When first securing the work and master their respective tables they are set that the centers the work, cutter, master point guided around the engraved and the cutter tapered angle according the drawing quirements. slightly different type graduated duralumin rings, mately in. outside diameter; hav For accu has atta mechar fed tions are cured transfe marking mach Work cut and neces and eng: identical The divided indicate every deg. are and the other every deg. rings are too large allow the usMere par ing table fitted with catch | | fy BD inf engines and other major accessories, there are number which not contribute directly plane production, yet are vitally impor- tant the industry. Among these specialized firms are those which various types engraving. Here review the methods carried John Meerloo Sons, described the British magazine Aircraft Production. having 360 accurately spaced teeth. For special graduations the standard catch plate can replaced one having different arrangement teeth. For cases where exceptionally accurate spacing necessary the firm ent depth opposite sides the die. careful choice cutter must made ensure that knife-edge tops are left the inscription. before, the graduations are cut indexing achieved from the teeth the catch plate the rear the table (Fig. 6). When the graduations are completed the figures are cut the normal manner from re- locking the pantograph mechanism masters secured the copyholder, has devised removable vernier for and feeding the table against stops; the stylus moving around the profile. attachment the circular table. For this work the pantograph tor ter ted 3—Surface grinding the backs interchangeable stamps ensure even marking when use. mechanism locked and fed against stops ensure gradua- tions equal length. When these are completed, sunk figures are se- the copyholder and, via the UPPER RIGHT 4—Flat ring- type dials which are graduated with the aid index- ing table. pantograph mechanism, their profile transferred the rings. ° marking dies are given Fig. and machine seen set for this RIGHT desigmWork Fig This time the metal ing figures relief, and great care leave the design necessary both when setting relief. engraving ensure that the tops is, the marking faces—are all identical. from the center verti- arranged dividing table, and that the work circumference ould result graduations differ- THE IRON AGE, October 4 — 2 LE j The finished die hardened and then ground wherever necessary. Another activity John Meerloo Sons the manufacture inter- changeable steel stamps, example which seen the center Fig. The stamp blanks enter the shop ground bar and are cut into suit- able lengths milling machine, few thousandths inch being allowed for grinding. These are placed singly vice the machine table and engraved with the requisite letter number from relief master the usual manner. Because the radius the cutter necessary clean out all sharp corners hand, intricate piece work when dealing with the smaller letters which may only 1/16 in. high. After hardening and polishing, the stamps are located inscription down- ward jig provided with slots into which they accurately fit. The assem- bly placed magnetic chuck and the base the stamps ground standard height from the letter face ensure even marking when placed the holder. Fixed stamps incorporating one more words are made engraving directly the machined face suitable forged shank. Another type die, for embossing sheet steel 750-ton press, may also seen Fig. two pieces, one with the letters relief and the other with sunk letters. this case allowance for the thickness the metal embossed made the sunk die. Considerable importance attaches the correct grinding the cutter, and for this purpose Taylor-Hobson type machine, designed specially for grinding standard engraving machine cutters, has been installed. Even the hands quite unskilled operators first-class results are obtainable with this equipment. the use range 6—Engraving roller-type die. For small work this nature magnifying glass used assist the operator. 7 7—Examples Meerloo engraving. the center interchangeable stamp and holder. clearance cams clamped the end the cutter socket, conjunction with cutter setting gage, the amount clearance needed can predetermined and repeated through- out the life the cutter. The rest which the cutter held swivels and can set any angle, although marked only with the settings most commonly used, that 10, 20, 45, and deg. addition the or- dinary conical cutters, cutters with parallel sizes can also ground fine limits. Effect Forging Bending-Fatigue Strength tion forging the fatigue strength specimens cut the longitudinal and transverse directions bar forged and heat treated stéel containing 0.32, 0.2, and Archiv fiir June, 1942. The results are compared with those given the literature for chromium-manganese-molybdenum- 60—THE IRON AGE, October vanadium steel and nickel-molybdenum steel. With speci- mens cut the longitudinal direction, the ratio fatigue strength tensile strength both smooth and notched specimens decreases with increasing reduction forging, and the notch sensitivity increases. With specimens cut the transverse direction, the above ratio also decreases with in- creasing reduction, but this case the reduction does not appear af- fect the notch sensitivity. The the fatigue strength the trans- verse direction that the tudinal direction both smooth and notched specimens decreases with ereasing reduction, and the fall the value this ratio greater smooth specimens than for ones. — u equ righ Slar dire arc. per trod carr development both auto- matic and are manual welding equipment specifically designed for the welding magnesium, mag- nesium alloys, aluminum and other high-strength light alloys under protective shield helium gas, has been announced General Electric Co. The availability such equip- ment should make possible the greatly extended use war production the lighter metals whose welding de- mands precise control concentrated heat and protection the molten metal from the oxidizing effect oxy- gen the air. The development the new equip- ABOVE um-shielded arc welding equipment operation. Electronic control panel right controls arc length. Slanting tube (lower left) directs filler wire into the arc. All operations are controlled panel up- per left. trode and gas nozzle are carried the rod perpen- dicular the work. 3—Close-up view welding magnesium plate. Extremely accurate control the rate feeding the filler wire into the arc (through tube left) produces the uniform bead contour shown the right. The nozzle just above the arc surrounds the molten metal with helium gas envelope. ment based research work initi- ated some time ago General Elec- tric’s welding laboratory and intensi- fied recently view the develop- ment and wider use the light alloy metals for war production. The basis this research was the pioneering work done years ago G-E engi- neers, Hobart and Devers, who discovered that fusion welding could done atmospheres helium and argon using tungsten and carbon electrodes. hint things come the are welding magnesium and other hard-to-weld metals given automatic unit, Fig. now use ° ° BELOW 2—Butt-joint in. magnesium plate au- tomatically welded rate in. per min. with G-E helium-shielded arc weld- ing equipment. Automatic Helium-Shielded Arc Welding the G-E welding laboratory. Com- pletely automatic, this equipment makes smooth, clean Fig. under shield helium gas rates in. per min. %-in. stock, for example. Fig. shows close-up view the welding magnesium plate. Substantially the same G-E unit now installed the plant large producer magnesium, this machine incorporates new electronic motor control which the equipment hold the proper length even while the are climbs and descends inclines, such encoun- tered welding curved surface parts. Referring Fig. the filler metal (magnesium, here) unreeled into the work the correct angle through the small nozzle rod the lower left. tungsten electrode used start and maintain the are extends through the center the rod perpen- dicular the work and the helium gas fed around the electrode. The rate which filler metal fed can adjusted uniform feed into the arc, supplementary con- trol can used feed wire into the withdraw it, and then feed again—all predetermined cycle. The heart-of the manual helium- shielded arc welding equipment specially designed electrode holder which arranged hold either tungsten carbon electrode and surround the electrode with stream helium gas. The source d.c. power for both manual and auto- matic welding standard G-E are welding machine. { | 4 q q q q q 4 or- the _ THE IRON AGE, Octob BELOW HIS gage saves time sorting mixed rivets, filling orders and checking incom- ing stock, and when used the assembly line prevents use wrong sized rivets. Rivet from 4/16 in. 20/16 in. are mea- sured across the width one side the gage. the reverse side, rivets from 20/16 in. 40/16 in. length are measured from the top the gage down. For determining the diameter the rivets, holes running 1/32 in. steps from 3/32 in. through 8/32 in., each hole being 0.002 in. oversize, are the bottom the gage. The in. unmarked hole key ring hole. The gage made gage cold rolled steel. 62—THE IRON AGE, October LEFT relatively slow drilling operations are replaced with one rapid, punching action, use the plate nut punch shown and illustrated diagrammatically. The punch was designed for use standard Chicago pneumatic No. 214 rivet squeezer punch the No. rivet holes for stainless steel plate nut installations. Since the No. squeezer exerts 3000 Ib. force for 3/32 in. the stroke, pressure approximately Ib. per sq. in. applied this punch. The stripping action performed two resilient rubber washers. The company estimates that the resulting reduction time required and elimination broken drills and burring operations will save approxi- mately $500,000 year. BELOW replacement rubber with cork blanking dies, shown above, has addition saving the company esti- mated $10,937 year, reduced installation time from hr. minimum average min., eliminated warping and denting, and reduced die spreading and breaking, for- merly caused the rubber becoming life- less. Cork ejects parts without sticking, there- increasing output, and while rubber must replaced every 500 900 parts run, with cork many 9000 parts have been run one die without noticeable change the cork. that measu steel roc the placing the rod outside mone Production Short Cuts bank WA INS \ ilk ° ° Here are some ingenious new time and money saving devices use Lockheed Air- craft Corp. and Vega Aircraft Corp., Bur- bank, Cal. Most the short cuts were devised workers the company. EJECTIONS spotwelds made imperfect electrodes with tips that have become too thin are eliminated the electrode and measuring device shown above. U-shaped scrap plywood and with handle that slides through hole one side the accurately measure the end thickness electrodes. placing the electrode end against one side the and inserting the rod until hits bottom, then measuring the distance between the outside the frame and the rod handle, the metal remaining the electrode tip determined. LEFT HIS for spot welding saves the company 876 man- hours yearly. Electrodes incorporate the quide the electrodes them- selves. ABCVE drilling thousands holes has been eliminated pin punching, shown above. The pins are placed the dies outside the trim line and the time the parts are formed the hydro-press, the holes, which ore needed order hang the parts racks for heat treating, are automatically punched. BELOW fixture shown below with motor mount ring makes possible motor mount rings projection welding machine approximately sec., the previous average time having been min. The fixture was designed for use 400 kva. Federal projection welder. Full floating electrode clamps, equally spaced deg., distribute the high amperage, voltage current. timer provides pulsations current for proper dissi- pation heat from the electrode contacts. The entire fixture clamped the upper and lower the projection welder. Since.the projection welding machine will exert force tons more, straightening the rings and lugs could accomplished properly spaced clamps and spacer pads. P x 4 for- life- ere- must with fun q THE IRON AGE, Octob sisting chromium steel castings, the rather low heat strength must borne mind. not modified any difference chromium con- tent. Table gives approximate data for the long term load different temperatures. this compilation load given which causes perma- nent elongation about per cent after 1000 hr. (The German standard creep test cannot applied.) Heat resisting chromium steels and chromi- castings exhibit strong expan- sion the long term road test, and reduction area similar havior the tensile test ele- vated temperatures. the impending rupture will pre- ceded the overloaded part deformation. Some examples practical ap- plications heat resisting chro- mium steel castings and chromium castings are given Table III. They show that, predominantly, mechanically unstressed parts are made from this material. The use the use the various scale-re- Brinell hardness avoided where heavy loads have high temperatures, for in- stance free bearing furnace rails. 64—THE IRON AGE, October 1943 order save chromium, alloys with chromium content have lately been introduced; however, creased silicon and aluminum additions have made. steels for forging and rolling, large saving has already been effected. Here the unfavorable effect con and aluminum the toughness hot work, but this improvement not sometimes even ™m So Bending Aluminum content, per cent 12—Influence aluminum content tensile properties cast iron with Si. deg. (Etched alcoholic HNOs). w Bending limit, possible casting. While consider- able experience has been collected the action silicon and aluminum additions pp. 155 160), hot worked and aluminum steels these experiences must yet accumulated for cast steels. though Scheil and Schulz (ibid.) showed that possible produce steel which scale resis- tant 2192 deg. the addi- tion per cent aluminum and per cent chromium, only steels are being made with higher chromium content and lower aluminum additions, for ex- ample, steels with per cent chromium and per cent aluminum. For castings only, iron with about per cent carbon and per cent aluminum used occa- sionally the manufacture fire gratings and similar parts. Fig. shows the influence increasing aluminum contents the strength properties cast iron with per cent carbon and per cent silicon. Hardness increases strong- with increasing aluminum content. The bend strength and bend limit, Fic. 15—Contains 5.70 Fic. 9.40 upon the structure cast iron with and after annealing 1740 howe stren have the alumi Figs. alumi tlenes cent graph Fig. minun 1830 erts tory 1650 cent quired. materi alumin cast tance sho rapidly per cer alun that been cart Pen Scale very bearing come Similar and these therefor tastings any cons SAM Resistant Steel Castings however, decrease owing increasing brittleness. For comparison, the bend strength and the actual bending effect of.a per cent chromium casting have been included. The reason for the increasing brittleness with higher aluminum contents can seen from Figs. 16. The graphite content cast iron decreases with increasing aluminum contents. Carbon bound aluminum-bearing special car- bide which causes hardness and brit- tleness. cast iron with per aluminum contains hardly any graphite. Fig. shows the influence alu- minum scaling air 1650 and 1830 deg. Although aluminum ex- erts strong influence, tory scale resistance reached 1650 deg. only with per aluminum, 1830 deg. about per cent aluminum would re- quired. cast iron, much alumi- num must added attain good scale resistance that very brittle material results. Three per cent aluminum suffices addition cast steel for working scale resis- tance 1830 deg. But toughness, shown Fig. 18, decreases more rapidly than the cast iron, that aluminum steel casting has no- ticeably lower toughness 1830 deg. than the chrome cast iron with per cent carbon. The stronger action aluminum the steel casting can probably attributed the fact that part the aluminum has been removed from the ground mass carbide formation, would hap- pen the cast iron. Bandel (Arch. 1937-38, pp. 144) showed that scale resisting aluminum steels tend very strongly take nitrogen- bearing gases. This difficulty over- when part the chromium replaced with aluminum that steels those proposed Scheil and Schulz result. Unfortunately, these steels also are very brittle toom temperature when hot de- formation possible. They can, therefore, used only for simple tastings which are not subjected any considerable heat stresses use. Complicated parts are difficult re- The alloys used Germany the manufacture creep and heat resistant castings are described this article, the first part which appeared last week. this concluding section attention directed particularly chromium-nickel steel castings, their physical characteristics and their applications. move from mold. Fundamental experiments the influence other alloy additions the toughness aluminum-bearing steels formed Cornelius and Bun- gardt (Arch. 1939- 1940, pp. 539 142) but unfortu- nately suitable means were found increase the toughness. Heat resisting steel castings with per cent chromium and corre- sponding aluminum contents can used this time only where tough- ness either manufacture use any importance. respect heat creep strength, this chromium-alu- minum steel behaves about the fer- ritic cast chromium; that is, the creep strength low and when the steel overloaded high temperatures the material breaks after very con- siderable elongation. Chrome-Nickel Highly alloyed chrome-nickel steels are used the manufacture heat resisting parts, first because their particularly high heat strength which can attributed the presence stable austenite, but also because increased toughness room tempera- tures. Table IV, the most suitable steels this group have been listed. High carbon contents improve cast- ability, which conditioned some extent the usual high proportion remelting scrap the charge. This scrap contains considerable amounts carbon, for instance, when the scrap case hardening retorts used. spite the comparatively high carbon contents which can lead the formation carbide mesh the grain boundaries (Fig. 19) and strong tendency transcrystal- lize, toughness quite good the as- cast condition room temperature (Table IV). slow cooling from high temperatures, numerous very fine carbide precipitations will take place the austenite grains and cause certain degree embrittle- ment. Fig. shows the position the heat resisting chromium steel the ternary system comparison with the stability limits the various phases after long term annealing Schafmeister and Ergang (Arch. Eisenhuttenw. 1938-39, pp. 459 464). Whether these stability limits which were determined chrome steels low carbon apply also Examples Uses Creep and Heat Resisting Steel Castings Parts subjected maximum steam pressure Parts for synthetic fuel manufacture and oil industry Burner housings, refractory helders, throttle dampers, door Stove plates, grates, burner door frames, tube holders, tube walls for high output boilers, carburizing boxes Carburizing boxes, annealing retorts, crucibles. conveyor rolls, burner stove plates, parts for stirring, furnace rails, TABLE Steel With Applications 3.00 Cr, 0.40 Mo* 4.00 6.00 Cr, 0.40 Mo** 7.00 frames, lead bath crucibles, flue dampers 14.00 Glass molds, door frames 18.00 25.00 chain members 30.00 Retorts for carburizing, burners for oil, gas and dust fuel, grates for high pressure boilers *Lately 1.00 Cr, 0.25 0.50 **3.00 Cr, 0.35 THE IRON AGE, October 4 it, 4 500 at /830deq- A a Aluminum content, per cent act tive those castings which contain sively for cyaniding pots, are the adhesion the primary Ste carbon, this time unknown. use this time. grain boundaries the chrome- per possible that the stability limits shown Table IV, the steel castings, while the inte- as-cas have been shifted rather high chro- nent load elevated the crystal has considerably Whi mium contents due the binding increases with increasing nickel con- greater heat strength. Also chrome- did off carbon chrome-iron-carbide. tent, although visible change the nickel steel tends strong transcrys- Steels 13, 14, and are, structure the steel does not and therefore develops Fig. 20, wholly partially composition per coarse primary grains. fluence areas where, after long term has been reached. surpris- The permanent load strength steel ing between 1110 and 1650 deg. ing that Steel 13, although containing steel castings greater per the brittle sigma phase can occur. considerable amounts ferrite, has that ferritic chromium cast- creased Where these types steel castings more favorable Therefore, increase the are used, care must taken that load strength than the ferritic chro- heat strength the chrome-nickel increas their service temperatures lie perma- mium steels. During the creep steel casting might expected in- nently above 1650 deg. Because semi-austenitic and austenitic the primary grain size economies, ‘these have nickel steels used castings tear the grain boundary material. de- mesh emg only from the fer- sets limits this procedure. The complet stressed parts such chromium castings which are small amounts titanium rails special furnaces which, be- room temperatures nitrogen, which causes refine- cause the particularly difficult ser- which will break only after consider- ment the primary grain the fer- 1.2 per vice conditions, the heat strength elongation high temperatures, chromium casting, does not offer 18, which were formerly used exten- permanent load strength deter- steel casting. Forging should sionally TAB Properties the Usual Heat Resistant Composition, Per Cent Yield Elongation Limit Tensile (Length=5X Steel Lb. Per Strength Diameter) Basis measurement permanent elongation per cent 1000 hours. IRON AGE, October 1943 ‘ act the same manner. compara- tive experiment with forged samples Steel did not show increase permanent load strength over the as-cast condition. While increased carbon content did not have noticeable influence the scale resistance chromium steels, chrome-nickel steels fluenced some degree carbon. steel per cent chromium and per cent nickel did not show in- creased surface scaling 2010 deg. air when the carbon content was increased, but was found the microscopic analysis that preferred scale attack takes place the carbide mesh along the grain boundaries. This attack, however, even quite distinct when the carbon amounts only 0.18 per cent, and can avoided completely only when the carbon very low. When the carbon content was increased from 0.18 per cent 1.2 per cent, increase the inter- granular attack was observed. There- fore, seems justified use occa- sionally increased carbon contents, if, Creep Lb. Per Sq. In. heat resisting chro- mium-nickel steels (ac- iron-chromium-nickel ternary system. 19—Structure heat resisting steel casting with Cr. and Ni. (Etched per cent concentrated HCL with per cent H.SO,) for instance, difficult castings mi- cro-pipes can thereby avoided. The high coefficient expansion these steels needs borne mind (Table IV). This fact particu- lar importance when chrome-nickel steel parts are built into ferritic steel constructions. Apart from the high heat strength some cases, the great toughness austenitic semi-aus- chrome-nickel steels can the most important consideration. The heat conduction just low the highly alloyed chromium steels. Castings from heat resisting chrome- nickel steels are nevertheless not nearly sensitive toward rapid tem- perature changes because their greater toughness temperatures red heat. The sensitivity toward sul- phur-bearing gases increases with in- creasing nickel content. However, this sensitivity will still within content per cent the chromi- content sufficiently high. number examples applica- tion heat resisting chrome-nickel Chromium Steel Casting Alloys Scale Resistance Nickel content, per cent steels for casting are given Table The use heat resisting chrome- nickel steel castings has lately been greatly limited order save nickel. this time, steel qualities are pre- ferred which contain small percen- tages (Steels 15) nickel and which are used mainly for stressed furnace parts such rails, charging boxes and chains furnaces. about 1740 deg. austenitic chrome-manganese-silicon steel (Steel 19) can replace chrome-nickel steel castings. This material, which has been use for number years rolling mill quality, has not been ap- plied the past castings because the disagreeable casting properties which apply all manganese rich steels. The temperature limit 1740 deg. for the application this steel due the fact that chromium cannot increased beyond per cent because the formation the inter-metallic compounds and also be- cause the manganese content un- favorable scale resistance. Rapatz (Stahl und Eisen 1941, Air Mean Coefficient Deg. Expansion Between 5700 1400 570 1830 1920 18.5 7.7 11,000 6500 2800 560 110 1740 1920 18.5 7.7 7100 3500 1400 140 1920 2010 18.4 7.7 11,000 7100 4000 2010 2100 17.6 7.8 11,000 7100 4300 2100 1000 199 2100 2190 16.9 8.0 11,000 7100 2100 1000 199 2100 2190 19.0 8.2 17,000 10,000 2800 1560 1740 20.0 7.8 THE IRON AGE, October 1943—67 r e i- e- 1e- fer ne- ald | 1073 1078) well Scherer, Riedrich and Kessner (Stahl und 1942, pp. 347 352) have reported other means saving possible suitable nitrogen addi- tions the chrome-nickel steel pro- duce stable austenite with consider- ably lower nickel contents. These ni- trogen-bearing chrome-nickel have excellent heat strengtk. the field foundry practice, nitrogen ad- ditions have become known only means grain refinement the fer- ritic chromium castings. the basis excellent experiences with rolling mill quality material, will neces- sary investigate also the influence nitrogen additions heat resist- ing chrome-nickel casting alloys. appears more difficult for the foundryman add nitrogen his product than for the maker hot de- formed steels, because the conditions solidification are strongly differen- tial the case casting and can easily cause nitrogen segregation the form blowholes. This danger steels TABLE Examples Uses for Chrome-Nickel and Chrome-Manganese Steel Casting Alloys Steel With Applications Tube suspensions, tube walls for high pressure boilers, parts heated one side only, for example flue dampers, similar 30.00 castings but for heavier mechanical stresses, not sensi- tive against heat and impact stresses, for example stirrers and lead bath crucibles. Rather insensitive toward bearing gases. Furnace parts, annealing retorts Carburizing boxes, furnace rails, annealing retorts, chain mem- bers, furnace parts for annealing furnaces, annealing feeders, troughs and plates for glass manufacture not usually great ingots and generally casting temperatures are higher the foundry than