The Iron Age 1943-11-18: Vol 152 Iss 21

EVERY BATTLEFRONT —keeping them flying, rolling, moving, every point where shafts turn, where motion must BALL BEARINGS at | | Z For more than years the Industry has shown its confidence Cleveland Worm Gear Drives continuing install thou- sands them throughout the Mill—from ore bridges inspection tables. THE CLEVELAND WORM GEAR CO. CLEVELAND OHIO GEAR SPEED REDUCERS THE IRON AGE, published every Thursday the CHILTON CO. (INC.). 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. 21. 4 Courtesy Republic Steel Corporation yst Office at VAN DEVENTER President and Editor BAUR Vice-President General Manager Editorial and Advertising Offices East 42nd St., New York Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout. ° ° ° Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. Cleveland Pittsburgh 1016 Guardian Bidg. Park Bidg. Philadelphia Chicago Chilton Bidg. 1134 Otis Bidg. PEIRCE LEWIS WARREN Detroit Hartford Conn. 7310 Woodward Ave. Box RAYMOND KAY Los Angeles 2420 Cheremoya Ave. ° ° ° Owned and Published CHILTON COMPANY (incorporated) Executive Offices Chestnut and Sts., Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH GRIFFITHS VAN DEVENTER Vice President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE THOMAS KANE Vice-President Vice-President ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers the Industrial Arts Index. Pub- lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents. ° ° 9 Vol. 152, No. IRON AGE Editorial Wanted—A Bond Holders’ Protective Committee. Technical Articles Developments the American Tin Plate Producing Tubular Railway Axles Chrome Ore and Chrome Magnesite Thermal Reduction Magnesium Compounds—I Current Zinc Electroplating Practice Needled Steel Specifications New Equipment—Small Tools Features News Front Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets Study 300 Months Shows Post-War Trends Large Assembly Units Assist Construction Third Installment Seized Metalworking Patents Personals and Obituaries Machine Tool News Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Prices Steel and Warehouse Prices Stainless Steel, Tool Steel Prices Semi-Finished Iron and Steel Prices Pig Iron Prices Ore and Coke Prices Ferroalloy Prices Index Advertisers November 18, 1943 100 104 170 172 174 175 176 178 179 180 181 181 184 185 186 267 4 — | | t — ° ° ° a Steel for weapons—for essential industries—steels for maintenance—special aircraft steels and alloys—all are immediately available Ryerson stocks! When shortages occur, Ryerson technical experience finds alternative. When speed paramount, Ryerson operat- ing men make delivery time. Call Ryerson first, whatever your steel requirements, for prompt, effective cooperation! Joseph Ryerson Son, Inc.; Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. L-SERVICE RYERSON 40—THE IRON AGE, November 1943 A 5 1 IRON ESTABLISHED ° ° Nov, 18, 1943 ° VAN DEVENTER President and BAUR Vice-President and General Manager DIX Manager, Reader Service ° Associate Editors MacDONALD BARMASEL Editorial SCHIEN WILLIAMS BUTTERS News and Technical CAMPBELL Pittsburgh 428 Park Bidg. Chicago 1134 Otis Washington National Press DONALD BROWNE EUGENE HARDY Washington National Press Bidg. LLOYD Cleveland 1016 Guardian Bldg. 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 JAMES DOUGLAS Seattle Wanted—A Bond Protective Committee normal times, bond buying primarily done people with larger than average incomes who choose this form investment because the safety principal involved. normal times, before the rubber dollar was invented the bond buyer who put dollar into this form investment had reasonable assurance that would even- tually recover that dollar and the meantime draw down moderate rate interest. Prewar sales stocks compared bonds ran about four five one measured market value. for kinds bonds bought, then, corporate bonds ran about five one demand compared with government issues. Today, everyone knows, this picture has changed materially. Government bonds are today’s best and everybody and his brother and sister are buying them the millions. Almost many government bonds are being sold and bought every day are pairs shoes. And course market value, there scarcely any comparison. Bond buyers customarily put their purchases safe places for pro- tection, “where thieves cannot break and these assets are threatened value more subtle influences, that vaults steel and concrete cannot repel, bond holders’ protective committees are ap- pointed protect the investors. With the majority American citizens buying government bonds today, would seem though these people could expect the admin- istration automatically become their bond holders’ protective com- mittee. And ostensibly, for publicity purposes. has been. The able but ill-fated former head OPA, Leon Henderson, for example, was the chairman our first bond holders’ protective com- mittee. Unfortunately had guts enough collide with and stand against certain powerful pressure groups with voting influence, whose interest was blow some inflationary hot air into our hollow rubber dollar. out went Leon. Chairman our bond holders’ protective committee today appears William Davis, chairman the War Labor Board, who has just this writing uttered blast against the inflationary effect wage rises. Unfortunately, because the emasculating operation re- cently performed Drs. Ickes and Lewis, this board now impotent withstand strike pressures for higher wages wet dishrag stand against hurricane. Coal has now opened the way for transportation, for steel, and for every other pressure group with potential fourth term voting power blow more air into our hollow rubber dollar the expense-of the government bond buyer. And also the expense every buyer and holder insurance, including the armed forces. Where does that leave us? You answer that one. Perhaps our only protection may elect real “honest God” bond holders’ protec- tive committee Nov. 1944. 4 — POST : | | | J | For Safety and 4/ With Inland Steel The buying public has learned associate steel with safety and dependability. People ride steel trains over steel rails, live and work structures made strong with steel, travel the highways steel automobiles, cross streams bridges steel, farm and manufacture with steel equipment, use steel furniture and innumerable household appliances all with the knowledge that these things, made steel, cost less, are more greater strength and safety. Steel affords strength without excessive volume and quickly recovers from strain, and resilient under shock. Steel reduces fire hazard the minimum, and practically unaffected climatic conditions. Steel normally resists corrosion and can easily more fully protected against such action. Steel absorbs neither moisture nor Inland has been leader the development steels meet changing industrial requirements— has continuously cooperated with industry make available various phys- ical properties and surface textures that give steel its un- surpassed flexibility product design and fabrication. The Inland laboratories and the Inland staff engineers and metallurgists are your service help you meet the design problems today and the post-war period. will glad help you any design, material selection fabricating problems. Chicago Illinois ¢ Milwaukee Detroit St. Paul St. Kansas City Cincinnati New head: shaf Moto degr stoc that that Hous atir tern - a tial air New News Post-war car models will probably have lower axle ratios which, though they rifice performance low speed, bring startling gas economies. miles per approximately miles per gal. can obtained with 3.0 rear axle ratio, against less than miles 4.6 ratio. Other probabilities are: transmission cases, differential housings and cylinder heads secondary metal aluminum castings; automatic transmissions; stiffer shafts; aircraft type bearings; pressure cooling; chrome plated piston rings; and system, one model for performance, the other for economy. Against normal productivity 4,000,000 cars year before the war, General Motors anticipates industry production for three four post-war years around 6,500,000 cars annually. Residual copper and nickel carbon steel heats has increased alarming degree West Coast open hearths. Heats have been rejected even for ordinary rolling stock. The public declaration Rear Admiral Cochrane, chief the Bureau Ships, that Puget Sound shipyards are overmanned, and the insistence Army Supply Services that tank and truck assembly lines moved across the mountains provide facilities and workers for aircraft, has done more clear the Pacific Northwest war production atmosphere than all the directives and expediencies applied date. Proposals relocate European heavy industry are being discussed high ment circles, with decentralization apparently the Whether contract termination negotiations will remain under the Army shifted the General Accounting Office will decided the House Military Affairs Committee, which last week examined termination practice the Chicago Ordnance District and accounting procedure Detroit. The sub-committee particularly impressed Ordnance's technique ating settlements, and will undoubtedly recommend continued Ordnance control over termination activities. Air cargo rates 15c. ton mile end billion ton-miles air cargo transport annually (1941 total: 5,250,000 were held out feasible post-war tials the recent SAE air-cargo meeting. Military types cargo and combat planes, which can serve the airlines cially only one two years, tend have relatively high wing loadings; will expensive reconvert, and compliance with stalling speed will affect allowable operating weight. But, they must utilized virtually the only immediately available the war's end. According high naval transport official, for 3000-mile flight, flying boat could carry per cent greater 1/3 less cost than land plane, but the land plane would arrive hr. faster. Standard specifications for needled steels specify base composition plus "sufficient intensifying addition" enable the steel meet specific physical property requirements. Ordnance has already adopted number tentative tions this type. Makers the various proprietary addition agents are, the light current needled steel tests, working recommendations for quantities and methods use that will bring practically the same end result with use any particular additive. new method impregnating magnesium castings with tung oil eliminates large proportion oil waste, saves time and results much larger proportion passing impregnation tests. The oil forced direct pressure rather the autoclave process. Aluminum castings never have been tight, aluminum goes, except for cylinder heads. Now all sand and permanent mold castings are short, are many magnesium aircraft parts, and all permanent mold castings. Too little casting capacity one reason. Serious manpower trouble foundries another. the West Coast, aluminum and magnesium foundry turnover per cent Overall, aluminum fabricating plants have turnover double the national manufacturing average. Development the American application tin coatings various metals hot dip- ping ancient art. About 1240 was extended tinning small iron plates Bohemia, and around 1620 the art spread Saxony but did not progress any extent until 1665. Andrew eventually learned enough the closely guarded about 1670. The Crown granted the rights and privileges tin plate manufacture William Chamber- lain 1691, and 1714-20 fair suc- cess was attained Pontypool. Prior this time, the industry had taken root Alsace and Saxony, but the real development was Wales the counties Monmouthshire, Glamorgan and Carmarthen. Wales had been favored nature for the beginning such industry, having the tin mines Cornwall, abundant water power, and indus- trious Welsh population. Significant progress was made when sheets were rolled 1728, replacing the old meth- hammering the base metal from iron bars. Credit for this accomplish- ment given Major John Han- burys. 1770 steam was substituted for water power and coke instead charcoal the production the wrought iron base. Other im- the first commercial production tin and terne plate the United States prior the McKinley Tariff Act. This plant was erected for the American Tin Plate Co., Wellsville, Ohio, 1873-74. Tinning was discontinued 1874 and the plant was purchased the Wellsville Plate Sheet Co., later being acquired the American Sheet Tin Plate Co. 44—THE IRON AGE, November 1943 portant changes occurred the meth- ods production; such the inven- tion the pickling machine, the annealing pot and the mechanical coating the plate. Siemens’ steel was substituted for charcoal iron 1875, and bessemer steel for puddled bar iron 1880. The growth the industry Wales was rapid. Table shows the pro- gression plants and the approxi- mate production certain years. From the year 1750 1891 the num- ber plants increased from while the number mills represented these works increased from 109 1858 525 1891. The growth the number plants and mills testifies the success the Welsh tin plate industry, particu- larly during the last years shown. This was largely due the tion steel for use base mate- rial, which turn permitted consider- able utensil technic ter the largely Welsh Whe Boys guard group: ultra- nition mo! was its chang that ignor from passe State King tin cario ket, tor t State neth- the nical steel Vales pro- roxi- ears, nted ticu- own. ider- — able technical progress tin can and manufacturing. While the technical changes occurring the lat- ter part the eighteenth century made very definite contributions the industry, its true strength was largely due the inherent skill the Welsh people. Whole families worked the mills. Boys started work early age and grew the trade. The indus- try was greatly decentralized and production secrets carefully guarded and largely confined family groups. This decentralization and ultra-clannishness did not contribute Welsh tin plate makers’ recog- nition the fact that while state monopoly had been attained, Wales was dependent upon the United States outlet for about per cent its total production, and concerted action was taken anticipate change this situation. The forces that had already established America industrial world power were ignored. Imports tin plate the United States from Wales had skyrocketed from 93,000 net tons 1871 367,- net tons 1889, but took the Tariff Act, which was passed the Congress the United States 1890, awaken the United Kingdom the realization that its tin plate industry was most pre- carious position, not only from the standpoint losing its largest mar- ket, but because universal competi- tor was prospect. Early American Attempts Early efforts establish tin plate industry the United States were feeble contrast the suc- the Welsh during most the nineteenth century. All tin plate was imported, and had never been sub- jected duties was the case other iron and steel products being manufactured the United States. duty 0.5c. Ib. was imposed tin Plate the Act 1862 and retained until 1864, becoming 2.5c. Ib. that time. Unfortunately, the increase was never actually put into effect. ° ° ° HOWARD KNOX Assistant Manager Sales, Tin Plate Division, Steel Corp. The history industry cannot fully recorded while still active. The purpose this article present general per- spective the progress the American tin plate industry, its dis- couraging beginning, its subsequent success the latter part the nineteenth century and its status the present time. this first part three-part article, the author discusses the early history tin plate and its development Wales, American at- tempts produce tin plate and the period immediately following the passage the McKinley Tariff Act 1890. There must have been some earlier efforts establish industry since shop Market Street, Philadel- phia, English tin plate was dipped into pot molten lead produce dull-appearing plate which was desig- nated terne plate. This plate was produced roofing material, and its worth was readily established. The process, however, promptly reached Wales for more favorable production. also reported that the first actual tin plate made America was produced Hussey’s Copper Works, Pittsburgh, 1858-59, one John Grey, the manager that establish- ment, the black plate being produced the Sligo Rolling Mills, Phillips, Nimick Co., built 1825 Pitts- burgh’s South Side. 1875 tariff rate which was about equal per cent the prevailing Welsh price, was put into effect and re- sult, 1872-74 three rolling mills with tinning equipment were built and operated. They were the Rogers Burchfield Co. Leechburg, Pa., the United States Iron Tin Plate Mfg. Co., Demmler, Pa., and Wellsville, Ohio, concern referred the American Tin Plate Co. (not the company “trust” fame). decline the price Welsh plate caused the latter company discontinue tinning 1874; the Leechburg mill 1875, Demmler plant 1877. The effect the reduction price might have been withstood degree except for the fact that there was marked lack technical information and ab- sence skilled labor this country, and that the rather limited steel pro- duction did not permit favorable costs match those the United King- dom. There was another change the tariff 1883, when duty lb. went into effect, but produc- tion was attempted since this duty was strictly revenue rather than protective nature. great deal this nation’s com- merce centered about the Eastern seaports, and was daily sight see thousands wooden boxes tin plate the docks many ports. This was particularly true Balti- more, which was the leading city both the manufacture cans and the packing food. Canned food was, then now, basic requirement for industrial nation such the United States, and dependency upon others for material was viewed with concern statesmen and industrial- ists alike. William McKinley was one the nation’s strongest advocates the idea that the enlarging demand for tin plate from the can industry and other users should satisfied American producers. Over 7,400,000 base boxes, valued well excess $33,000,000, reached this country 1889, but that year marked the end the balmy years for Wales since enterprising America caused the Con- gress the United States enact the McKinley Tariff Act 1890, giv- ing protection lb. against imported tin plate. The McKinley Tariff Act out- standing example timely legislation designed protect infant indus- try long the industry could progress. The act contained provi- sion that the duty would removed entirely the American industry THE AGE, November 1943—45 ° 7 7 | failed produce certain amount plate June 30, 1897, namely that the amount tin plate produced any one year between July 1891 and June 30, 1897, had equai one- third the plate imported during any fiscal year this period. this provision was not met, protection was cease. Here was challenge American industry that was readily accepted. attribute the beginning the tin plate industry this country the McKinley Tariff Act. This protective tariff hastened its start, but was inevitable that American ingenuity resources would have eventually accomplished the same results some later date. New Plants Stimulated McKinley Tariff Act was not operative until July, 1891, but dur- ing 1890 number tinning plants began appear. Mills rolling light gage sheets hastily installed tinning equipment and other rolling mills were built with the necessary finish- ing Approximately plants began operations 1891, with more under construction. Due the lack sufficient domestic black plate, considerable tonnage was im- ported from Wales, fact about per cent the tin and terne plate produced 1891-92 was made from foreign black plate. The location the early tin plate concerns was influenced the possi- bility supplementing existing roll- ing mill equipment with tinning fa- cilities, source semi-finished steel for rolling, the existence fuel and labor, existing consumers such manufacturing stamping en- terprise. Certain Atlantic Seaboard companies who had been importing tin and terne plate looked upon Amer- ican manufacture substitute. Areas consumption had con- sidered. Although not entirely accurate, general geographic classifications may established from the basic reasons outlined. Pittsburgh, western Pennsylvania, and the eastern Ohio areas had rolling mills producing sheets, supply semi-finished steel, labor and fuel. The Atlantic Sea- board had former importers and was large consuming area. The Middle West had plentiful supply natu- ral gas and was adjacent the pack- ing sections Indiana and Both the East and Middle West had their existing fabricators tin plate. The concerns coming within these ge- ographical locations, with supplemen- tary notes, are follows: PITTSBURGH, WESTERN PENNSYLVANIA AND EASTERN OHIO AREA: was with pride and satisfaction that the community Demmler, Pa., saw its mill, the United States Iron Tin Plate Mfg. Co., in- dustriously start producing tin plate 1890, undoubtedly with some the equipment which had been forced shut down years before. John Hamilton, Pittsburgh, was one the first buy black plate lo- cally, 1890. Laufman Tin Plate Co. built plant 1890 Butler Junction, buying black plate from the Apollo Sheet Iron Mills, Laufman Co., Ltd., Apollo, Pa. Apollo Sheet Iron Mills, Apollo, Pa., added tinning equipment their rolling mill 1891. Cadwallader, Pittsburgh, in- stalled tinning equipment 1891. Wallace Banfield Co., Irondale, Ohio, added tinning equipment its rolling mill 1891. New Castle Steel Tin Plate Co., New Castle, Pa.—1892-93. TABLE Growth the Welsh Tin Plate Industry 1750 Year Works Year Mills Year Base Boxes* 1750 1858 109 1875 3,000,000 1800 1868 171 1887 11,000,000 1825 1878 13,000,000 1860 1891 525 1865 1870 1875 189! base box area 218.78 sq. ft. (31,360 in.) the equivalent area sheets— 46—THE IRON AGE, November 18, 1943 Aliquippa Tin Plate Co., Aliquippa, Pa.—1892. Blairsville Rolling Mill Tin Plate Co., Blairsville, Pittsburgh Tin Plate Works, New Kensington, Pa.—1891-92. James Scott Co., Allegheny City, Pa. (Pittsburgh), did tinning only—1891-92. This concern later be- came the Follansbee Brothers Co. Monongahela Tin Plate Co., South Side, Pittsburgh, 13th Street and P&LE Railroad—1893. Record Mfg. Co., Conneaut, Ohio, bought black plate for tinning for use its can manufacturing business— 1891-92. Britton Rolling Mill Co., Cleve- land, Ohio, added tinning equipment its rolling mill 1893. EASTERN AREA: Iron Clad Co., Brooklyn, Y., installed equip- ment 1890 tin black plate for its own consumption stampings though the company had been tinning manufactured ware since about Cumberland Steel Tin Plate Co, Cumberland, Md., 1891 was one the earliest sheet mills supply black plate the numerous Eastern ning establishments that came existence after the McKinley Penn Treaty Iron Works, Marshall Brothers, Philadelphia, 1891 added tinning facilities their rolling mill Taylor Co., Philadelphia, which for years had been identified with manufacturing tin plates Wales, moved its equipment 1900 the company built its own ing mill Cumberland, Md., eventually was purchased the public Steel Corp. Baltimore Tin Plate Co., Locust Point, Baltimore—1891-92. Matthai, Ingram Co., Baltimore —1892. Later owned and operated the National Enameling Stamping Co., St. Louis. American Tin Terne Plate Philadelphia. Installed tinning ties 1891-92. Somers Brothers, Phillips Tin Plate Co., Inc., delphia, established tinning facilities 1892. Norristown Tin Plate Co., Norris town, Pa.—1892. Merchant Co., Philadelphia, stalled tinning equipment 1893. Philadelphia Iron Tin Works; Hughes Patterson, Philadelphia, added tinning plant its rolling mills 1893. MIDDLE WESTERN AREA: Louis Stamping Co., St. Louis, large fabri Mills the built duce tion ing Ohio Piqu ning first coun rely toa grea whic can and heat and know Stam ite Ind.- the tin 1893. Fint new cons weld surf each pass tube tube june ppa, New heny and Ohio, r use ess— its nning 1876. one black added elphia, terne ipment the ated amping Co, facili- Norris- 1893. plant EA: is, large fabricators tin ware, added tinning equipment its Granite Iron Rolling Mills 1890. This concern was later known the National Enameling Stamping Co., and today the Gran- ite City Steel Co. American Tin Plate Co., Ellwood, Ind.—1891-92. This plant was one the largest and was the first complete tin mill constructed. Morewood Co., Gas City, 1893. Indiana Tin Plate Mfg. Co., At- lanta, Ind.—1892-93. Later became the Atlanta Steel Tin Plate Co. Norton Brothers, Maywood, built tinning plant 1891 pro- duce tin plate for their own consump- tion can manufacturing Simpson Co., Cincinnati— 1891. Later the American Galvaniz- ing Tin Plate Co. 1900. Cincinnati Corrugating Co., Piqua, Ohio, bought black plate from the Piqua Rolling Mill Co. and began tin- ning 1891. Welsh Labor Used was only natural that during the first few years manufacture this country the industry was forced rely upon Welsh methods and labor considerable extent. One the greatest obstacles overcome was the breakage equipment, most which had been imported from Wales. was real innovation when Ameri- can engineers increased the diameter and length hot mill rolls. Greater heat radiating efficiency was secured and more pressure could exerted Ind.— 2—Trade mark the American Tin Plate Co., wood, Ind., 1891. The American eagle carrying the British the replacement Welsh tin plate the American prod- uct. reduced the packs* longer lengths, and with the larger rolls was pos- sible maintain more uniform and *The black plate for tinning was hot rolled from bars into two sheets which were doubled and redoubled with inter- mittant heating and rolling. constant temperature. The best indi- cation the progress this period found record domestic produc- tion contrasted with tin plate im- ports. Production this country was approximately 1118 net tons 1891 contrasted importation from Wales that year 516,766 net tons, but 1892 output had reached 21,060 net tons. Conditions this country during that year did not warrant importation from Wales greater than 210,919 net tons. The close 1893 saw the domestic tin plate output the year before almost tripled, result- ing tonnage 61,803 net tons against imports 314,048 net tons. There was still plenty room for more productive capacity since Amer- ica’s needs were far from being ade- quately met. Ed. Note—Next week the author continues with discussion the pe- riod competition and subsequent combination and corporate expansion. The effect improved can design the expanding use tin plate also described. Gas Cooler Improves Furnace Operations insure better control anneal- ing, drawing, tempering, and stress relieving operations, the Brown Fintube Co., Elyria, Ohio, designed finned tube gas cooler. The cooler Welded extended surface fintubes, welded headers each end and mounted insulated steel housing. Water for cooling through the inside the tubes, while the gases cooled are Passed between the outside the tubes and the unit housing. The cooling units are used con- Junction with two furnaces, shown Fig. The hot gases are with- drawn from furnace tempera- tures ranging from 1200 1600 deg. F., while this furnace the heat- ing cycle, and are passed through the cooler which reduces their tonnage any desired level. These cooled gases are then passed into furnace and careful temperature control the cooled gases, the work furnace FURNACE FURNACE annealed, drawn, stress re- lieved, exact temperature that will produce desired physical quali- ties. After furnace has been re- charged and put back heat, the cycle reversed and the material furnace goes through the secondary cycle. Advantages claimed for the fur- nace gas cooler are, addition temperature control annealing, stress relieving, and drawing, that time cycles are greatly reduced speeding the cooling cycle and there absolute control furnace atmosphere assuring minimum oxidation. THE IRON AGE, November 18, 1943—47 > | Producing Tubular Railway Axles Tubular railway axles offer greater physical strength and in- creased resistance wear the journals well substantial savings weight over solid axles. The procedure the Pittsburgh Steel Co. making these axles and the results experimental tests are herein described. velopment work, the Pittsburgh Steel Co. has completed addi- tion its Allenport, Pa., plant devoted the production tubular railway axles. The new product represents one the few major developments railroad rolling stock design recent years. The plant, which has capacity 500 axies day, involves novel fea- tures design and has made full use production line methods. While the patented process and tests were com- pleted three years ago engineers the Pittsburgh Steel Company with the cooperation the Urschel Engi- neering Co., the difficulties con- structing new plant not directly de- voted military materials under war conditions delayed putting the project into operation until the present time. several years de- During this period, however, some axles produced experimental basis have been actual railroad service. The new plant, which uses seamless tubing its material, adjoins the com- pany’s Pilger mill which supplies the tubing cut suitable sizes. The Pil- ger process unique method pro- ducing seamless tubing. After cylin- drical billets are pierced, the rolling process differs fundamentally from the usual method completing the tubes. The rolls used form the tubing are elliptical and they rotate di- rection opposite the feed the steel which pressed against the rolls The steel fed forward the ram when the pass between the rolls wide. the pass narrows, the rolls produce effect similar the blows forging hammer. The inside diameter the tubes main- tained the use mandrel. resulting product has the superior qualities which naturally result from forging operation comparison rolling operation. After being cut suitable sizes, the tubes are taken the axle plant The and are passed through tube end heating furnace which heats one end each tube. The heated ends then are upset tube upsetting press and the ends are then shaped form the journals and wheel seats the axle 3000 lb. drop Following this operation, the tubes are returned the heating furnace, and the opposite ends are heated, up- set and forged. normal operation, each alternate tube new while the adjoining pieces are going through the process for the end. The axles which have been finished both ends then pass hardening furnace, and after ing, they straightened and quenched. The straightening quenching equipment designed that the ends the axles are plugged, and quenching takes place only the outside. Fig. solid and tubular axles for in. journal. FROM HERE HERE DIMENSIONS ARE SAME HOLLO AVES WEIGHT SOLID AXLE TAPERS TOWARD CENTER HOLLOW HERE SAVES WEIGHT—GREAT- NOT NEEDED FOR OUTSIDE DIAMETER GIVES 48—THE IRON AGE, November 1943 WHEEL SEAT STRENGTH THAN SMALLER SOLID AXLE FROM HERE HERE TUBULAR AXLE STRAIGHT pro join Aft sist stri 300 ing ins ma chi ple tul are the tio tul ani cer ins are main- The from sizes, plant nuous heats ends etting Seats tubes ration, going inished emerg- and and esigned lugged, the RIGHT Material for tubular axle production seamless tubes produced the ad- joining After heating continuous tube end heating furnace, the first operation con- sists The heated end each tube held die while the press strikes the end in- crease diameter. BELOW—RIGHT 3—After up- setting, the jour- nal and wheel seat are forged drop ham- mer. Following com- pletion one end, the axles turned the heat- ing furnace conveyor and the opposite end normal operation, each ternate axle hav- ing the second end finished. Following quenching, the axles are passed through forced convection draw furnace and then through cooling tank. final operation, the insides each end are simultaneously machined exact centers special machine and are ready for shipment. Axles Interchangeable The axles are designed ma- chined the same journal and wheel seat dimensions the conventional type solid axles. They are com- pletely interchangeable axles and can machined the usual types lathes with the addition suitable fittings for centering the tubular material. Between the wheel seats the axles are straight and are left with the na- tural finish produced the Pilger mill operation. The only difference the outside dimensions the por- tion between the wheel seats, since the tubular axles not have the fillet and the subsequent taper toward the center, which typical solid axles. The relative shapes well the inside contours the tubular product are shown Fig. which compares halves tubular and solid axles. Substantial savings weight result from the use the new product well greater resistance distor- tion and greater fatigue resistance. The saving weight per axle, shown Table varies from 177 axles with 5x9 in. journals 510 THE IRON AGE, November nals. These savings weight range from 25.1 per cent 42.8 per cent. Railroad operating officials report varying estimates the cost haul- ing one ton dead weight per car per year the basis 10,000 miles operations year. These estimates range from $12 $18 per ton per car per year. Assuming average cost $15 per ton per car per year for hauling dead weight, 50—THE IRON AGE, November 1943 LEFT 4—The form- axles are heat treated tinuous hardening furnace. ° ° BELOW 5—After pass- ing through the hardening the axles are straightened and then are quenched specially signed machine. quenching the ends are that place only outside. would range from $7.53 for 40-ton cars equipped with 5x9 in. journals $15.30 per car for 70-ton cars with in. journals. The saving unsprung weight also materially reduces rail hammer and may expected result sub- stantial ultimate saving mainte nance way expenses when cient number cars become equipped with tubular axles. More important than this, however, the saving maintenance cost secured through longer life the tubular axles with far less frequent replacement. Two types tests were the axles. The first part consisted termine stiffness under various loads. these tests, collars were fitted the wheel seats with the same toler- ances with which wheel press fits are made. was found that the tion tubular axles was less than that solid axles under equivalent load. the solid axles, failure through permanent distortion began 169,000 and continued the loads were increased. Actual yield occurred 225,000 Ib. 226,000 Ib. For tubular axles, loads 369,600 431,000 lb. were required set the structures permanently. This in- dicated per cent greater strength for the tubular axles over the solid axles before plastic deformation veloped. ken ing tub tol axl sult q acco 0-ton with also and ost the ployed sisted loads. ted toler- its are than ivalent failure began yield 000 369,600 set in- trength solid ion de- ° Following quenching the axles pass through forced convection draw furnace and cooling tank. the final operation the ends are simultane- ously machined centers. Fatigue tests were conducted the physical testing laboratory the Tim- ken Roller Bearing Co. with the axles loaded the basis 19,000 lb. break- ing stress the wheel seats. The tubular axle withstood over 88,000,000 stress reversals which was equivalent 155,000 miles in. wheels, with- out failure. Similar tests with solid axles 19,000 lb. break stress re- sulted failure the wheel seats 875,000 2,755,000 stress reversals. The greater physical strength the tubular axles attributed sev- eral factors. First, the greater ex- ternal diameter between the wheel provides greater strength than the solid axles. Second, the tubular material, produced the Pilger process, forged product with the usual physical benefits conferred forging. Third, subsequent heat treat- ing further improves characteristics. The heat treatment id TABLE Comparative Weight Solid and Tubular Axles Weight Journal Weight Weight Weight Reduction, Sizes, In. Solid, Lb. Tubular, Lb. Reduction, Lb. Per Cent 705 528 177 25.1 835 575 260 31.1 1,015 632 383 37.7 1,190 680 510 42.8 also makes the tubular axles less sub- addition laboratory tests, ject wear the journals. further advantage been found, according studies made plant engineers, that tubular axles run cooler which should prove fac- tor making them less susceptible wear and some types hot boxes. cannot secured until large num- bers the axles have been ser- vice for some period time. numerous axles produced ex- perimental basis have been actual service railroads for several years. one these service tests, tubular axles and solid axles were placed the same trucks heavy dump cars used the Monessen Southwestern Railway. Considerably less wear was found the tubular journals than solid journals especially endwise after identical periods service. Protective Skin for Plated Surfaces HAT said new and effective method lastingly protecting and cadmium surfaces against corrosion through the appli- new coating, Iridite, has been developed Rheem Research Products, Inc., Baltimore, ary the Rheem Mfg. Co. Iridite, chemical coating ap- and cadmium surfaces. Simple use and low cost, Iridite, according the Rheem, literally ‘ ‘soaked up” the plated metal, be- coming integral part it. will not flake off chip. The color olive drab. The protective skin pro- vided Iridite extremely thin, and under ordinary conditions 100 gal. Iridite solution will coat 20,000 sq. ft. work. Plated parts are treated with the Iridite dipping them proper solution for from sec. and then immediately rinsing hot water facilitate drying. The only equipment needed for ap- plying the coating, which despite its extreme thinness not impaired bending, forming twisting, acid-proof container for the soluticn and container for the hot water rinse. temperature from deg. 100 deg. used for the sclution, the exact temperature de- pending upon the work done. Iridite must not used protect containers for edible products. THE IRON AGE, November 18, 1943—5! | 1 ——_— q | q Chrome Magnesite Chrome Ore Concluding his two-part article, the author discusses the manu- facture chrome and chrome magnesite brick and its properties and applications, well those other composite refractories containing chrome. Last week, the distribution, properties, condi- tion and preparation chrome ore were investigated. one time, straight chrome brick made grinding chrome ore with water and possibly little gum, molding, drying and firing, was one the principal steel plant refrac- tories. Very little straight chrome brick used today, being usual add least per cent magnesia the batch. When straight chrome brick made, considerable difficulty experi- enced due softening during firing. avoid distortion, the bricks are often boxed with silica brick, which makes the production the chrome brick rather expensive. Moreover, such brick has low refractoriness under load failpoint (2550 deg. under lb. per sq. in.), after they are fired. Both these difficulties can overcome sufficient magnesia added the batch react with the serpentine other gangue material chrome brick usually contain such addition together with chemical bond which gives them high green strength. Chrome bricks show shrinkage firing characteristic refractory batches consisting relatively in- ert ‘grog’ surrounded fusible matrix. Fig. shows the type curve obtained when the firing shrink- age measured continuously. with magnesite brick, the after-contraction obtained fired chromite brick simply continuation this firing shrinkage. has shown that certain types Fig. firing shrinkage curves for Cuban chromite test pieces. -2.0 100 120 140 160 180 Minutes 52—THE IRON AGE, November 18, 1943 CHESTERS Central Research Department, United Steel Companies, Ltd., Stocksbridge, England ° ° ° chrome ore, when heated re- ducing atmosphere, show abnormal expansion comparatively low tem- peratures (Fig. 9). doubtless this reaction which responsible for the crumbliness both chrome and chrome magnesite brick made from these ores. With chrome magnesite bricks, which normally have strength about 3000 lb. per sq. in., the use such ores may lead bricks hav- ing strength 1000 lb. per sq. in. less and porosity per cent more. Such bricks are not con- sidered satisfactory only because they not possess adequate “edge- strength” and suffer serious damage handling. The mechanism the reaction has been the subject great deal re- search, but the results have not yet been released for general One point, however, clear, those ores which contain free iron oxide received, are readily oxidized firing (when they become strongly magnetic), are among the most sus- ceptible this type failure. Chrome-Magnesite Brick The chrome-magnesite brick used today relatively recent develop- ment. number workers Ger- many, America and Great Britain developed approximately the same time brick similar type (70-30 chrome-magnesite) having properties much superior those straight chrome brick. Not only did they pos- sess much higher refractoriness un- der load but, suitably graded, they showed very high thermal shock resistance, The most usual procedure for the ap ° ° ° in sir on ter | 7 the tre alc ve} ne: bri re- for and rom ngth use hav- cent con- uffer has re- yet ation. those ongly used Ger- ritain same (70-30 raight pos- un- they shock ‘or the approximately 7-25 B.S.S. mesh (8-28 Tyler mesh) and the per cent magnesite all the fine frac- tion—through mesh. B.S.S. (65 Tyler mesh.) Other combinations hav- ing these properties can used, but the above far the most usual batch composition. The brick may either chemically bonded and used unfired may fired the normal way. Further, may made hand-molding or, more usually, hydraulic press hammer machine. The effect the grading the thermal shock resis- tance shown Fig. 10. will seen that the highest thermal shock resistance was shown the coarser mixtures. increase the percent- age fine (and lesser extent medium) material, resulted much lower thermal shock resistance. The drying chrome-magnesite brick does not present the difficulty experienced with straight magnesite, since the chrome ore inert mois- ture and the proportion magnesia relatively small. The firing treat- ment varies very considerably from one plant another, the finishing temperature being low 2460 deg. little doubt that high firing tem- simulates the furnace conditions with- out resulting any serious loss thermal shock resistance. One for- tunate feature these bricks that the fired length close that the mold size and hence allowance for shrinkage expansion need normally made. Preliminary heat treatment the chrome ore, either alone with magnesia, has been ad- vocated but not employed Great Britain. the chrome-magnesite ratio dif- fers from the 70-30 composition given above, either towards the magnesite chrome end, the same degree Shrinkage compensation (or expan- sion) not obtained. The results given series laboratory test. pieces are shown Fig. 11. the amount magnesite required con- vert serpentine associated with the chrome forsterite calculated, will found only about half that actually employed. not surprising that this should the case when realized that the mag- nesia solid throughout the reactions and unlikely come contact with all the serpentine present. The changes occurring during the manufacture chrome-magnesite brick are not limited the conver- sion the serpentine forsterite. That some reaction occurs between 2.0 Chrome ore (Grecian) Expansion, per cent | 500 1000 1500 2000 2500 3500 6.0 ore | Expansion, per cent w 1.0 500 deg. 9—Thermal expansion Grecian and friable African chrome The temper- atures adjacent the curves indicate the maximum heat treatment the specimen had received prior testing. Black and white dots indicate tests made reducing and oxidizing atmospheres respectively. the magnesia and the chrome ore can readily shown using electrically fused magnesia, which starts colorless crystalline material and fin- ishes with reddish-brown tint which strongest the outer surface and disappears towards the center the grain. Chemical analysis magnesia grains removed from such mixtures shows them contain traces iron oxide and chromic oxide. consider- able amount work has been done Trostel and other workers, but there would still seem some doubt the mechanism the reactions which occur. One thing, however, clear; the spinel does take the reaction and not the stable and inert material that was once con- sidered be. Some use has been made, particu- larly Germany, brick containing per cent chromic oxide prepared fusing various slags, for grading the ther- mal shock resistance 75/25 chrome site brick sieves used, 100 Coarse (7-25 mesh) example, those from ferrochrome pro- duction, and casting them the form blocks. Sittard gives the composi- tion the remainder alumina cent, miscellaneous oxides per cent. Such blocks have been found give good service the ports and the front and back walls basic open-hearth furnaces, but their high price likely hold back their more general adoption. Patents have also been taken out for other synthetic cast refractories, for instance, those made from aluminachromic oxide batches. Chrome and Chrome-Magnesite Properties chrome and chrome- magnesite brick have already been discussed connection with the ports Per medium (25-72 mesh) THE IRON AGE, November 18, 1943—53 | | | | | | ted } + + | | at | & ° ° ° / \ / \ / / / \ /\ \ / / Expansion firing, per cent Chromite, per cent acid open-hearth furnaces. (THE IRON AGE, May and June 1942). already mentioned, such brick characterized its low refractori- ness under load and relatively low thermal shock resistance. Though these limitations have been largely overcome the more modern product, their principal advantage still their relative inertness contact with both magnesite and silica. The properties chrome-magnesite brick have also been discussed pre- vious articles the all-basic fur- nace and the basic open hearth (THE AGE, Aug. and 22, 1940, and May and 29, 1941). addition the properties there discussed, two other physical tests have yielded in- teresting data. far back 1931 was shown, means high temperature tensile tests, that 50/50 mixtures chrome and magnesite could heated higher temperature without failure than either magnesite chromite when used alone. More recently, tor- sion tests carried out the Univer- sity Leeds (Fig. 12), have shown that even temperatures, chrome-magnesite brick not behave elastically; that is, when subjected torsional stress they not recover completely when the stress removed. the test repeated with rising 54—THE IRON AGE, November 1943 LEFT ex- pansion con- traction chrome- magnesite mixtures. RIGHT 12—Effect stress application and release chrome magnesite test pieces tem- peratures 1200 deg. Note per- manent set even the cold. Torsional stress, temperature, found that the amount the permanent in- creases until 1830 deg. very considerable. This capacity chrome-magnesite brick: yield under stress without rupturing accounts, least part, for its high thermal shock resistance. Brick made from magnesite chro- mite alone shows such marked ten- dency, being practically elastic its behavior until well above red heat. That other factors are, however, in- volved thermal shock resistance shown the fact that most magne- site brick made from sea-water mag- nesia has high thermal shock re- sistance (30 reversals) and yet elastic least 1650 deg. Earlier articles the fur- nace have dealt length with the bursting chrome-magnesite brick contact with iron oxide. still considered that this one the main ‘causes failure chrome-magnesite brick when used open-hearth fur- nace roofs. The process solid solu- tion iron oxide the working face has been very clearly demonstrated Hugill and Green the serial photomicrograph reproduced Fig. 13. service, the gradation from the working face the unchanged brick relatively slow, and hence the pho- tograph shown was taken from lab- oratory prepared sample. Chrome- Brick The features are, however, charac- teristic those observed under ser- vice conditions, namely, absorption iron oxide the chrome grains the working face and the tendency for the silicate matrix react with the incoming iron oxide; product passing into the brick away from the working face. Recent X-ray examination samples removed from basic roof after weeks’ service, showed the existence zone about in. from the face that was rich forsterite and lite Analyses the various zones sug- gested that part, least, the lime has been picked from the furnace atmosphere. The roof question was suspended system levers and dead-loading, that the skewbacks were capable movement during heating and cooling weekends. The fact that they showed movement due the absorption iron oxide the working face confirms the opinion that the latter plastic condi- tion when the furnace top tem- perature and that growth simply re- sults “slabbing off.” This greatly since opening the joints detaches large areas that would otherwise have remained place for long time and protected the undamaged brick be- hind. per cent Magnesite, per cent Vertical Torsional strain (twist) radians radian) lir na sil for the action away X-ray from about ich lime was and The ement condi- tem- re- reatly oling, have and be- Expansion, per cent w The remarkable rate which this expansion, due so