The Iron Age 1943-11-25: Vol 152 Iss 22

a. 25, 1943 IND ice its. Beat punch; step the per- formance your equip- Bearings. neck bearing measured what does—not what looks like. You can’t gauge the potential life bearing its appearance. It’s the intangibles that count— the things you can’t see; inherent qualities essential performance, endurance and economy. These include superiority de- sign; suitability material; and the experience and facilities the manufacturer. They are the qualities that give Timken Roll Neck Bearings the great- est life expectancy (measured tonnage rolled) and the lowest bearing cost per ton rolled; they are the qualities that make Timken Roll Neck Bearings your best buy. The Timken Roller Bearing Company, Canton, Ohio. ett | WELDING POSITIONER Backed many years experience de- veloping positioners and special fixtures for welding and other requirements, Whiting QUICKWORK \DIVISION position offer complete engineering machines with capacity twenty tons more, Whiting positioners are engineered the particular needs the particular plant. CORPORATION Such service assures new efficiency and econ- 15601 LATHROP AVENUE, HARVEY, ILL. omy both installation and operation. service this type equipment. From small hand-operated units large THE IRON AGE, published every Thursday the CHILTON CO. (INC.). Philadelphia under act March 1879. yearly North America and South America, Foreign $15. Vol. 152, No. Entered second class matter November 1932, the Post WHITING q t ost Office at VAN DEVENTER President and Editer BAUR General ° ° and Advertising Offices Johnson, Market Research Hayes, Production Manager. Baur, Typography and ° Regional Business Managers York New York 42nd St. 100 East 42nd Cleveland Pittsburgh Chicago Chilton Bidg. 1134 Otis PEIRCE LEWIS WARREN RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY (incorporated) Executive Offices Chestnut and Sts., Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President HILDRETH GRIFFITHS Vice-President TERHUNE Vice-President DEVENTER Vice President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretory CHASE THOMAS KANE DUFFY CHARLES HEALE ° Member, Audit Bureau Circulations every Thursday. Subscription Prige America, South America and $8; Foreign, $15 year. Copy, cents. ° ° Vol. 152, No. The IRON AGE Editorial Splitting the Elephants ° ° Technical Articles Drawing 105 mm. Steel Cartridge Cases. Thermal Reduction Magnesium Compounds. Torpedo Tubes for Surface Development the American Tin Plate Basic Cupola Process for Post-War Russia, Market for American Invisible Ink Identifies Employees Rubber Dies for Small Presses Features News Front Assembly Line Washington West Coast Fatigue Cracks Dear Editor News and Markets Closing More Open Hearths Predicted Most Steel Consumed Production States Another Installment Seized 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 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 Goke Prices Ferroalloy Prices Index Advertisers November 25, 1943 199 ° ° ° 126 130 Member, Associated Business Papers 131 {hp 134 138 139 139 142 143 YORK-HARTFORD PHIL from another. The color scheme recently introduc- Engineer will gladly explain how this AGE ESTABLISHED 1855 ° ° Nov. 25, 1943 ° ° VAN DEVENTER President and Editor BAUR Vice-President and General Manager ° ° DIX Manager, Reader Service ° Managing Editor....... LIPPERT News, Markets Editor...D. JAMES Technical Editor......... OLIVER WINTERS ° ° Associate Editors MacDONALD BARMASEL BUTZNER Editorial Assistants SCHIEN WILLIAMS BUTTERS Regional News and Technical Editors CAMPBELL Pittsburgh 428 Park POST Chicago 1134 Otis Bldg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bldg. 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 St. Louis JAMES DOUGLAS Seattle Splitting the Elephants Patrick McCarran, Nevada, has made proposal which, understand being taken seriously, not only his home constituents but also number his fellow legislators. that somebody, preferably private enterprise, immediately start build big steel producing plants every state the union, the capacity these new plants equivalent our total present steel producing capacity. Naturally, since normal demands for steel for peacetime operations have never been able utilize full capacity existing facilities—pre- war utilization over 10-year period has been about per cent—this means splitting abolishing present units. And this reminds story. Once upon time, long before the first man introduced himself the first lady that day with the statement: “Madame, I’m Adam,” the current ruler the animal kingdom, who was advanced thinker, got bright idea. “There too much variation size between the various members kingdom,” said he. “Take and ants. The latter are great disadvantage because elephants can step them and put them out business without even knowing it. should even things making elephants smaller and the ants bigger, thus giving everyone fair chance.” Now happened that the differences size between elephants and ants and between other members the animal kingdom were not matters chance choice, but functional differences that were dic- tated natural laws. However, what chance has natural law when bumps against the opinions and desires unnatural law maker? the ruler proceeded pass law. nothing did. Ants continued small and elephants large. called meeting his wise ones and councilors and laid the problem before them. Said the wise ones: “Oh King, not know how make ants large, but know how make elephants small. Let’s cut them into little pieces each big elephant will become lot small ones.” the chief veterinarian was called and instructed carve the elephants. But alas, after had done was found that the dismem- bered parts were longer elephants but pieces flesh that had more life them and had buried quickly keep the atmosphere from being polluted. This taught the would-be maker unnatural law lesson. learned that some animals have big fulfill their intended func- tions and some small. Perhaps can apply that wisdom today. The public might indeed well served having peanut stand every corner but would indeed ill served applying this procedure steel plants. Ag | = :) 4 REEN ¢ 4 EC 2 YOU’LL FIND INLAND PLATES Offices: MILWAUKEE DETROIT 44—THE IRON AGE, November 25, 1943 North, east, south, west... Throughout the Seven find Inland plates Victory ships, escort vessels, And landing barges. find more Because many cargo ships Will delivering Combat tanks, jeeps, bombs, Gun carriages, ete. Made from steel Rolled Inland Indiana Harbor. Today, during all the war months, Inland men and women Are keyed the job producing quality steel help bring keep America free. INLAND STEEL CO. ST.PAUL ST.LOUIS KANSAS CITY CINCINNATI NEW YORK | 4 : ~~ was qwarded n for ‘our Army~ wr. News IRON NOV., 25, 1943 Either Germany close defeat some serious American production are prospect. official remonstrations against complacency way offset widespread repetition the reports imminent German collapse such one said have been brought back very high WPB official who was just flown and out Sweden Mosquito bomber. War agencies and individual manufacturers are the process frantically squeezing out material pipelines—reflected immediately open hearths going out production last week. All sudden, agencies, companies and individuals seem imbued with the Key personnel continues leave WPB, and after year's end likely will only shadow its former self. And: From one end Washington the other, from top bottom, the fight for post-war planning power the only subject now given serious attention. step 40,000 tons monthly this December. Now, contracts have been and December output will zero. Alloy steel output has dropped the lowest level since June, 1943. Open demands have dropped under capacity, with some marginal units going off, and able addition slackening immediate prospect. The Maritime Commission, using over one-third the country's steel output and about nine month's steel supply yards, has far started But, started, the effect steel production will quick and dramatic. Meanwhile: Additional steel producing units are continuing built, the same time recently completed DPC units are idle. Flying instruments which year ago were holding aircraft assemblies are now such good position that production being cut back. some instances small plants converted from other products are doing better job than large instrument makers, although development naturally still concentrated the larger plants. Promising results are obtained with machines the blanking and forming small parts, with many economies tool equipment previously thought possible only with large hydraulic presses. Russia's position heavy industrial goods customer immediately after the indicated the fact that per cent coal and coke, per cent iron per cent iron and steel, and per cent machine building production the U.S.S.R. has been destroyed. Half Willow Run's aircraft manufacturing has been subcontracted, reducing manpower requirements 100,000 workers 50,000 Scrap brokers and dealers are wondering (and worrying) over the probable effect the trade wartime establishment 75,000 salvage managers the nation's plants, and industry's increased savvy and interest scrap. Though total imports raw materials the fiscal year ended July $2,750,000,000, the 146 Government purchasing programs accounted for only $1,300, 000. this, all but $117,000,000 was brought through private importers. The plight the small scrap dealer those areas carrying shipping point near the $14 OPA floor (South, Southwest and New England) becoming increasingly desperate, and shipments from those points are drying rate. Important changes scrap price policy and consolidation scattered administration over scrap metal are presaged White House report aimed back the peddler and small dealer. new stimulant employment women being tried the West Coast. Company's maximum October been made employment ceiling, With further male employment ceiling number male employees October, less per cent. [= } | 4 q | | q 7 4 4 | » | q J q q | Drawing 105 mm. Steel Cartridge Cases ORMALLY producer metal stampings used the fabrica- tion wide range con- sumer products, Mullins Mfg. Corp.’s Youngstown Pressed Steel Division, Warren, Ohio, was among the first plants feel the tightening grasp government limitation orders the manufacture civilian items. With what seemed the ease quick-change artist, but reality in- volved serious thought, planning, and engineering, say nothing con- siderable expense, the production was quickly shifted the manufacture war materials including variety stamped metal items, brass cartridge Disc blank 4.324 dia. 0054 Third draw 46—THE IRON AGE, November 25, 1943 | Fourth draw 1G. with steel disk, shown the upper left, the process forming 105 mm. steel cartridge cases consists two cupping operations one shown here); five drawing; pre-heading, two-stage heading; and tapering draw. There little dimensional change the base thickness metal, the walls being formed entirely ironing out the metal above the base ring. b series two articles the manufacture 105 mm. steel cartridge cases and 105 mm. high explosive shell for use those alc cases Mullins Mfg. Corp. will described. The following deals qui wifh the 105 mm. steel cases. eac run cases, and other products required for 105 mm. shell and high explosive the American and United shell for cases this size. armed forces. had previously been making 105 mm. Two the most interesting conver- cartridge cases, but Jan. sions made Mullins were the 1943, line for production steel manufacture steel cartridge cases 0208 First draw Trim before fifth draw cases was started. present, work Second draw Trim before heading Fifth draw cas thi pie | progressing maximum speed two steel shell case lines, the second going into operation March 1943. the short space about eight months, this company rose the position the foremost manu- facturer 105 mm. steel cartridge eases the country, supplying up- wards per cent all cases this size and type used. The 105 mm. steel case one piece case, drawn from steel disk series two cupping, five draw- ing, and one tapering operation, along with the necessary steps re- quired form and machine the case head and primer hole. Fig. shows each step except pre-cupping order operation. The steel used the manufacture this particular type case special Army Ordnance Department cartridge case analysis, running about 0.22 0.32 per cent carbon and 0.45 0.75 per cent man- ganese. The choice steel for this item was difficult, since there were specific properties desired that some ways opposed each other. First, the finished case must all times form stable container for the powder charge. must act obturator, that is, must able expand and form seal between the case and the gun barrel prevent firing gases from escaping through the breech. However, addition these properties and paradoxical the lat- ter, the steel had such that would contract after firing that the case could automatically ejected from the breech. Pre-cupping the disk blank received from the mill, 7.261 in. diameter one face and 7.385 in. diameter the other face, the edges, course, be- ing slightly tapered. The stock 0.515 in. thick and the disk weighs 6.1 lb. This disk then pre-cupped, step that draws shallow cup from which forming can started and which serves check whether not the steel will withstand drawing strains. This pre-cupping operation shown Fig. the disks being de- livered the operator inclined channel. Annealing gas-fired furnace relieves stresses set the steel the pre-cupping draw and the shallow cup then pickled. This pickling done lead lined tank, the bath being heated steam coils the bottom the tank. clear water rinse follows the pickle. One the most important phases the process manufacturing the 105 mm. case the cleaning system employed. While sufficient lubrication various types lubricants from heavy greases light water soluble oils the punches and dies highly essential, important that the shell cases clean when placed annealing furnaces. Any oil for- eign matter deposits the material would cause charring annealing and leave carbon deposit the steel that might affect further drawing operations. Hot water sprayed with considerable force each part fol- lowing the drawing operations ac- complishes this cleaning function. The cupping draw, 400-ton press, the second forming step. The base thickness the cupped disk throughout the drawing operations 2—(Left) This rack arrangement feeds steel disks the operator the pre-cupping press. Pre-cupping merely forms shal- low cup start the drawing operations and acts check the the steel. pre-cupped disk shown the operator's hand. (Right) intermediate rawing operation. THE IRON AGE, November 25, | | | sive nm. q § — remains quite constant, but the wall thickness reduced the case wall lengthens, can observed from Table and Fig. The cupping punch and die arrangement shown Fig. The punch action the steel disk pressed against the die sets the steel kneading action. This forces the cup very tightly around the punch. facilitate removing the cup from the punch the up-stroke the ram, the stripper leaf fingers hook the cup edge, holding place the punch These stripper leaves are backed coil springs and are rounded the top sides. Thus, when the cup forced through the die the punch, the stripper leaves are backed out the way. However, their flat under- sides engage the cup edge the punch withdrawn. The finished cup passes through the bottom the press into tubular earrier that runs under the floor spray where the cups are, one time, force-spray washed with hot water remove press lubricating oil and dirt. the press ram comes down, forces cup into the die, which turn forces the previous cup into the tube. With each successive press stroke, the cups move station through the spray the un- loading platform. The cups are un- loaded into wire tote baskets and are annealed and pickled the same fol- lowing the pre-cupping operation. After the pre-cupping and cupping operations, there series five drawing operations between each 48—THE IRON AGE, November 25, 1943 livers which the case annealed, pickled, and washed. All draws formed hydraulic presses using Carboloy dies. The first Hy- dro-Dynamic type 150-ton press. The operator shown Fig. stationing the formed cup this first draw press. The second draw 100- ton press, the third press, the fourth 75-ton press, and the final draw performed two 75-ton presses. holder purich Carbide cupping A ABOVE the this cupping opera- tion, forces the cup through the die which further forms it. the cup falls below the die, the stripper leaves en- gage the cup edge, stripping from the punch the punch The cups pass into tubular arrangement through the bottom the press that de- them washing spray. Following the second draw and prior annealing and pickling, the bottom the cup, which rounded shape, flattened for forming the case head. This pre-head- ing done 1000-ton mechanical press. Following the fourth draw, addition the pickle and rinse, the dipped into soap solution. This soap solution, made one soap chips per gal. water, facilitates the final drawing operation, Prior the fifth draw, the top mouth end the case rough trim- med length roll trimmer. the pre-cupping and cupping operations, which use tool steel dies, the arrangement shown Fig. However, the drawing opera- tions, carbide dies are used. Details this type die setup are shown Fig. The stripper leaf arrange- ment for removing the case from the punch slightly different here than the cupping dies, can seen the illustration. Here the stripper leaves are forced downward instead backward the cup passes through the die. The stripper leaves then spring over the edge the cup forced below the ends the leaves. coil spring stripper leaf brings into stripping position. Then, the punch with- drawn, the leaves catch the cup edge, forcing the cup off the There annealing pickling following the fifth and final draw, the BELOW 4—This operator about position the cup the first draw- ing press. The cups are annealed and pickled between each draw relieve strains the metal and break elongated grain structure set previous draws. case then being headed and dented. These operations are performed one two-stage 1500-ton press. Since the amount cold working the case head great extent determines the physical properties the steel, this A f/f / Die clamp plate t a Die Aolder the tion. one ater, dies, Fig. hown the than ipper asses cup the each pping with- edge, kling the Hardened stee/ Bumper (Part press) ram Second heading First bumper Heading post nose Cartridge case die Die support ring Post screw Die holder rests Post sections Note: Knock out part press 5—This punch and die setup typical the drawing presses. Car- 6—This two-stage press arrangement used head boloy dies are used and the punch stripping mechanism slightly dif- ferent than that shown Fig. the cupping press. This the third draw die assembly. step important. Care must ex- ercised that cracks not appear the head cold shuts appear around the primer hole. forming the head this two-stage manner, the chances these defects occurring are re- duced. The first punch Fig. 6—is bulged slightly the center the shape shallow seg- ment sphere. The metal thus forced flow toward the outside edge the case head, well filling the the punch that forms the thickened center part the case through which the primer hole drilled. The second bumper—B Fig. 6—is flatter than the first and forces the excess metal the edge the head toward the center the case head, thus adding metal the primer and the same time work-hardening the head. The primer hole indentation performed the first die setup, and together these two press operations get the desired metal hardness the case head. The finished shell from the head the mouth constant taper, which fitted with taper die. The case mouth pushed into restricted die ring, pressure being applied the head the case. This shown the steel case. Heading bumper convex force the metal the toward the outer edge, forming the flange. The second bumper, less convex, permitting the metal flow toward the center the case head. This thickens the boss through which the primer hole machined and serves work-harden the head metal. Fig. where the case can seen positioned but the ram has not yet descended. The head the case fits into the hollow base the ram, 7—The case tapered this press. The ram forces the case down into hollow tapered die which gives the finished taper. THE IRON AGE, November 25, led TABLE Characteristics Cartridge Case After Individual Draws | Reduction Base Thickness, Wall Thickness Case Diameter Wall Thickness Type Die Operation In. Mouth, In. Mouth, In. Per Cent Used Press Cupping... 0.510 0.325 4.972 Tool Steel 0.510 0.208 4.759 Carboloy 2nd 0.510 0.133 4.580 Carboloy 3rd 0.380 0.084 4.503 Carboloy 4th 0.380 0.054 4.420 Carboloy 5th Draw... 0.380 0.033 4.328 Carboloy primer hole machined. The second machining merely finishing cut the counter-bore and taper the primer hole. this point, where completely formed cartridge case exists, there inspection station. The case gaged, the machining and primer hole checked, and the length the case gaged. passing inspection, the ° ° ° which forces the case down into the taper die. Machining Following the tapering draw, there are two machining operations per- formed finish the case head. The first automatic chucking IG. 9—These sections the steel cartridge case after each manufacturing operation illustrate how the bottom head thickness substantially maintained, while the wall thickness reduced form the case these drawing operations are quite severe, annealing necessary between each press pass. 8—To relieve stresses set the case mouth the tapering draw, the mouth an- nealed salt bath furnace. The cases are loaded racks and placed into the bath batches, shown here. machine. The wall the case near the head turned proper diameter, the shoulder machined from the case wall into the head, the head flange thickness established, the head machined proper thickness, and rough counter-bore the case washed internally and exter- nally alkaline spray washing machine remove all lubricating oils, soaps, grease, rust from handling, and other foreign matter. The case then trimmed finished length. Case Mouth Anneal salt bath anneal for the mouth the case, shown Fig. relieves stresses set tapering. The bath liquid saltpeter and the cases are held place specially designed rack through which the cases are dropped, mouth downward, catching the case head flanges. This rack handled overhead hand crane, the cases being changed batches. clear water rinse removes adherent salt, and then the cases are placed stress annealing oven. This an- nealing furnace continuous, re- circulating type, gas-fired, the cases being drawn through the heating zone moving chain conveyor. From the stress anneal, the cases are loaded cooling conveyor, overhead moving line, which passes them through water spray the inspection stations, one which i ‘ 50—THE IRON AGE, November 25, 1943 cut the etely case the xter- shing oils, lling, case th. ieves bath are igned are ching rack rane, erent an- cases zone cases asses the which Pre-cupping steel disk, 200-ton hydraulic press. TABLE Operations the Manufacture 105 mm. Steel Cartridge Case (39) Inspection flange and head diameter and head thick- Inspection, visual for cracks and surface defects. ness. Anneal, gas-fired annealing furnace. Taper case wall, 75-ton hydraulic (4) Pickle, steam coil heated tank. 41) Inspection, visual for scratches and material defects after Rinse, clear water. tapering. Cupping, 400-ton hydraulic press. (42) Machine: Body head proper diameter; shoulder Force spray hot-water wash. case head; flange thickness; head thickness; and rough Anneal, gas-fired annealing furnace. counter-bore primer hole automatic chucking machines. Pickle, heated tank. (43) Finish machine counter-bore and taper primer hole 10) Rinse, clear water. drill press. First draw, 150-ton Hydro-Dynamic type press. (44) Inspection machining; position and forming primer 12) Inspection case wall thickness. hole. Anneal, gas-fired annealing rurnace. 14) Pickle, heated tank. 15) Rinse, clear water. 16) Second draw, 100-ton hydraulic press. 17) Force spray wash, hot water. 18) Inspection case wall thickness. 19) Prehead, 1000-ton mechanical press. 20) Inspection head thickness. 21) Anneal, gas-fired annealing furnace. 22) Pickle, heated tank. (23) Rinse. (24) Third draw, 100-ton hydraulic press. 25) Inspection wall thickness. 26) Anneal, gas-fired furnace. 27) Pickle, heated tank. 28) Rinse, clear water. Fourth draw, 75-ton hydraulic press. 30) Inspection wall thickness. 31) Anneal, gas-fired annealing furnace. 32) Pickle, heated tank. 33) Rinse, clear water. 45) Wash, internal and external, alkaline spray washer. 46) Inspection: Case gaged, machining checked, primer hole checked, and case length gaged. (47) Trim case wall finish length, roll trimmer. 48) Salt bath anneal case mouth. 49) Clear water wash remove adherent salt from salt bath anneal. (50) Full case anneal, recirculating type gas-fired anneal fur- nace. (51) Cool, conveyor and water spray cooling. (52) Final inspection Mullins and Army: Profile check; taper check; inspection head diameter, body diameter, flange thickness, case length, wall thickness case mouth, primer hole depth and contour, and primer hole counter- bore depth. Visual examination for surface defects inside and outside. Inspection for metal laminations after pickling, visual. Pickle and chromite dip, preparatory Paint inside and outside case, with phenol formaldehyde varnish, spray booth with water back drop for exhaust- ing air paint fumes. 34) Dip into soap solution for draw lubrication. Paint drying, infra-red drying ovens. 35) Trim case mouth rough length. (57) Primer hole painted, hand spray. 36) Fifth draw, 75-ton hydraulic press, two presses use. 58) Paint inspection, visual. 37) Inspection wall 59) Packaging, nine cartridge cases corrugated paper car- (38) Heading and denting, 1500-ton two-stage hydraulic press. ton, for shipping. operated Mullins and the other the Army Ordnance Depart- ment inspectors. this point, in- spections are rigid and complete. profile gage, simulating the breech 105 mm. gun, gages the wall taper. Subsequently, head diameter, body di- ameter, head flange thickness, case length, wall thickness the case mouth, primer hole depth and counter- bore, and case finish are inspected. The cases then progress through pickle and chromite dip which cleans and prepares the metal surfaces for painting giving them rust-re- sisting film. This bath heated steam coils. Following visual in- spection for laminations after this chromite dip, the inspection approval stamp applied and the cases pro- ceed the painting department chain conveyor. Painting specially designed spray booth the cases are sprayed internally, ex- ternally, and the bottom, being held upright position pins that fit into the primer holes. The cases are delivered the sprays circular conveyor. The cases, toward the spray, trip control that turns the spray on, and, the spraying cycle complete each case, the spray automatically turned off. forced draft blows the spray fumes into water wall which washes them into the sewer. The coating used phenol formaldehyde bakelite base varnish. From the spray, the conveyor carries the cases long bank infra-red drying Various inspection stages through- out the forming operations are set recurring nature the formation the steel cases, such off-register dies, scoring the case from foreign material cracks the dies, etc. These inspections begin with visual inspection following the pre-cupping. Wall thickness inspected after each draw, and after preheading the case checked for head thickness. After the heading operation the flange di- ameter well the head diameter and thickness are gaged. After taper- ing, the case visually inspected for blemishes; and after ma- chining the case inspected for proper machining well for po- sitioning and forming the primer hole and counterbore and for case length. Starting with 6.1 steel disk, after forming, trimming, and machin- ing, the finished case weighs 5.1 metal loss about lb. Careful check case wall hardness must maintained that completion the case will uniformly hard, with Cutaway sections the drawing steps the manufacture the case are shown Fig. The drawing operations cause quite severe reductions the thickness the case wall and work harden the metal that anneals are necessary between draws prevent splitting. Once the shoulder between the case wall and what eventually becomes the head established, there metal drawn from the head, the walls being formed from what metal extends be- yond the shoulder. perform this shaping, the wall thickness must greatly reduced and extended longitudinal direction. Table the reductions draws are shown, ranging from per cent the pre- cupping operation per cent the fifth draw, the most severe all. The wall thickness the case determined the difference dia- meter the punch and the die. These differences vary slightly with the draw and tend reduce the drawing THE IRON AGE, November 25, | | | A | i 4 q | i process was sufficiently perfected allow its application com- plant. American Magnesium Metals Corp. founded Nippon Mag- nesium Metals, Osaka, together with Nippon-Chisso, Japanese fer- tilizer concern. 1935, the first plans and designs were made for erection unit the plant site the above mentioned company Konan, Korea. 3000 kva three phase furnace was erected, and the beginning the oil paste method was installed. The rotating table baking machine men- tioned previously was erected granulate the magnesium dust the oil paste method. Vertical shaft fur- naces were also installed for dis- tillation the granulated magnesium dust. The paste baking equipment and the shaft distillation furnace were entirely new development that time, and the company was quite conscious that much experimentation would necessary develop these systems commercially. the end 1936, the plant started operate, but with interruptions,. during the Fall 1934, the magnesium Black Mountain College, operation larger scale many new problems occurred. The baking the dust with hydro- oils was later given up, and dry dust presses Also the operation the continuous shaft furnace was still very unsatis- factory. Because the difficulties described before, the author has come the conclusion that the problem continuous distillation the magnesium dust, while not insoluble, needs much for final solution. capacity production with the Korean plant, 1937 new batch distilla- tion system was developed Konan, which was simple and immediately successfully. The liquid condensation the metal was replaced sub- limation process, condensing solid The method consists providing ring shaped space inside 13—Magnesium ring weighing about 1500 removed from the retort Konan. The ring solid metal, with only the surface crystals. retort, which space filled with the magnesium dust tablets (Fig. 12). The retort made mild steel in- serted electric resistance fur- nace means gas light flange, and both retort and the furnace are evacuated. this arrangement the mild steel wall temperature about 1400 deg. released from outside stresses caused atmos- pressure. Therefore retorts quite large dimensions can con- structed without the necessity using heat resistant steel alloys great wall thickness for the retort body. the sublimation process, the metal condensed the form solid ring the surface move- able sleeve inserted the top the retort. This ring had weight, Konan, between 1200 and 1500 and showed surface the inside (Fig. 13). The experiments with this type sublimation process were already started the time the hydrocarbon baking method was still use. Dur- ing that time the observation was ° ° ° 12—Section through subli- mation Retort and Furnace, first time used 1936 Konan and larger scale Permanente. Flange closes gas-tight the electric heating furnace that can put under vacuum inde- pendent from vacuum inside re- tort. inserted sleeve the magnesium crystallizes 4 4 44 U7 44474 made ing the diffic and geth and ing. form gate for ing into table with high step step the + redu (Fi IRON AGE, November 25, 1943 WT made that any hydrocarbon remain- ing the granulated mass disturbed the the magnesium the sublimation process. was dificult drive out the baking process the heavy hydrocarbons even temperatures about 1100 deg. F., and these hydrocarbons evaporated during the sublimation vacuum to- gether with the magnesium vapors, and caused the troubles condens- ‘ing. The hydrocarbons prevented the formation solid metal ring, and caused the growth fine aggre- gate crystals. such form, the magnesium was for remelting, the fine crystals gave high burning loss during the melt- ing process. The solid magnesium ring, later produced from the dry tableted dust can easily remelted with burning loss not much higher than per cent, whereas fine aggregates give burning loss per cent. the remelting the sublimated product the last step the process, the yield this step essential for economy, any loss this step affecting the total cost the process. The possibility producing metal- magnesium with the carbothermal reduction process was established be- yond any doubt the Konan plant. Using 3000 kva reduction furnaces (Figs. 14, and 16) and using hy- drogen chilling gas with power cost mills per kw. hr., the total production costs the metal cast into solid bars was between and per Ib. Konan was selected for the plant site because the fertilizer plant Nippon-Chisso had large installa- tion for producing hydrogen elec- trolysis. The original plan was have the electrolytic hydrogen pass the magnesium plant first, picking about per cent carbon monoxide and have this gas, after the usual methods chemical purifica- tion, later supplied the catalytic ammonia plant. order not dis- turb the ammonia process any irregularities the magnesium plant, final arrangement was made use hydrogen gas cycle after remov- ing the monoxide washing out with ammoniacal copper solu- tion. Any moisture contained the chilling gas would affect the yield Magnesium, water vapor reacts with metallic magnesium this fine Compounds. Concluding his two-part article, the author describes commer- cial development the carbothermal process for reduction magnesium compounds, which the inventor, Permanente plant and Korea. addition discusses broadly other methods reduction, and the commercial future mag- nesium. Part the article, presented last week, dealt detail with experimental development the carbothermal process. distribution, forming magnesium ox- ide and hydrogen. The washing process with copper solution saturated the gas with moisture that the hydrogen was dried with silica-gel before entering again into the mag- nesium process. the end 1938, the Japanese 14—3000 kva reduction furnace erected 1935 Konan, Korea. the center, the furnace body visible with control panel for gas flows. the right side the expansion chamber, top the charging device, where raw material briquettes were charged from moveable bin. THE IRON AGE, November 25, ith 2). in- ur- are the ‘om 10S- on- or 15—Top the furnace shown Fig. 14. Note the 8-in. graphite electrodes and the glands with cooling pipes. such closed furnace practically cold the outside, transformer installed close furnace, shortening heavy bus bar lines. company erected second unit and April, 1940, the time the author left Japan for good, the erection third unit was contemplated. Dur- ing all these years vast experience was accumulated concerning the de- tails furnace operation, tableting and sublimation the metal. the Fall 1940 the author lived the United States, and was, officer the American Magnesium Metals Corp., interested the ex- pansion magnesium production the United States. January, 1941, negotiations were started between the Henry Kaiser interests and the American Magnesium Metals Corp., and the Kaiser group bought the patents covering the carbother- mal reduction process. The author was appointed consultant for the design and erection the Permanente mag- nesium plant. the total production the Permanente plant was contemplated 12,000 tons year, was course not possible use 1000-ton units like those developed Konan; also, the retorts had enlarged reduce their number. The natural gas com- ing ftom California gas fields con- tains mainly methane, very small amounts carbon-dioxide and nitro- gen, and small percentage the higher homologs methane. The Permanente cement plant uses about 17,000,000 cu. ft. gas day for the burning cement clinker and lime rotary kilns. was planned conduct this gas first the mag- nesium plant use it, instead hydrogen, chilling agent, and, after having picked about 54—THE IRON AGE, November 25, 1943 per cent carbon monoxide, conduct this gas the rotary kilns where used fuel. There was lot speculation and argument among chemists whether the natural gas, mainly consisting methane, would split into hydrogen and car- bon, would form other hydrocar- bons upon coming contact, even for short time, with the magnesium vapors and carbon-monoxide mixture temperature 3600 deg. But what was already known about the stability methane, led the belief that the time contact high temperature would too short have any considerable influence methane gas, which many times more stable than liquid hydrocarbons. But there were many changes in- troduced the Permanente plant, compared with the plant Korea. was decided first erect one unit with capacity 3500 tons year, and later multiply the plant ca- pacity adding more units. The difference between the plant Per- manente and the one Konan were considerable can seen from Table Even these changes were quite considerable, was expected the problem could mastered with all the experiences accumulated since 1930. The plant was have trial open- ing September, 1941, and the large reduction furnace operated imme- diately full satisfaction. Only one difficulty occurred: The dust did not tablet, that the retorts for sub- limination could not charged. the management the plant had committed itself produce metal for date, was proposed overcome this difficulty temporarily intro- ducing the old method coalescing the magnesium dust magnesium grains disclosed Hansgirg U.S. Patent No. 2,025,740. For this purpose temporary ar- rangement was made fill the re- torts directly with the magnesium dust coming from the reduction fur- nace by-passing the tableting ma- chines. During the filling the first retort, unfortunately rubber con- nection piece opened and magnesium dust flew out the air, catching fire and burning four workers badly that they lost their lives. This accident, entirely unconnected with the normal plant operation, renewed all the tremely dangerous operation. The plant management, influenced group engineers very much favor the hydrocarbon chilling process, insisted the elimination the dry-tableting, and going back the old process, used 1934 Austria, baking the dust with hydrocarbon oils, already described Hansgirg, U.S. Patent No. 2,101,904. previously explained, this hydro- carbon paste method was used Konan large scale and given there uneconomical. The author made every effort that time influence the plant man- agement toward studying the possi- bility dry tableting the dust scientific way, and investigating why the dust produced Perman- ente did not tablet, while that pro- duced Radenthein, Konan and Swansea, England, tableted easily. would have been easy find out the process elimination whether chilling with natural gas, differ- ence raw materials, certain electrical conditions the reduction furnace were responsible different behavior, but, unfortunately, the management insisted the hy- drocarbon paste method primitive equipment special equipment for baking this paste was used. The paste was di- rectly charged into the sublimation retorts, and from these retorts the hydrocarbons were first distilled off (Fig. 17). Later, raising the tem- perature, the magnesium was covered sublimation. The number retorts was previously carefully that the additional time neces- sary drive out the hydrocarbons, the time cycle the retorting plant was entirely disturbed. Many other inconveniences occurred that the carbo- a aft ble rtain ‘come scing ar- re- fur- ma- first con- ching This with 1ewed The ion back with cribed man- possi- ust rman- pro- sily. out hether differ- the nately, hy- talled. this mation led off tem- refully hr. neces- arbons, plant because the fact that these retorts were never designed for distilling hydrocarbon oils. All this could have been overcome. But the distilling off the hydrocarbon oils the sub- limation retort itself results dis- turbance the sublimation process the heavy hydrocarbons, which are partly distilling the same time the magnesium starts sublimation. has been previously mentioned that the presence hydrocarbons the sublimation retort prevents the forming solid magnesium ring, and the metal deposited com- paratively loose crystal aggregates, which causes great losses remelt- ing for the purpose casting the metal into ingots (Fig. 18). Finally, with all these temporary adjustments, the plant unit was oper- ating quite successfully with reduced capacity until the time Pearl Harbor. Unfortunately the writer this article, enemy alien born Austria, was detained days after Pearl Harbor. With the exist- ing rules, his further connection with defense plant was longer possi- ble. The month before Pearl Harbor, the plant management had already de- cided use hydrocarbon oils chilling agent for the second unit, and entirely new plant was designed Permanente engineers for that system. chilling agent, low boiling hydrocarbon oils, which evapo- rate during the chilling process and later are condensed together with the magnesium dust, should forming thin slurry from which the magnesium dust has separated. was proposed use electro- static separation method, had al- ready been used successfully for the de-waxing hydrocarbon oils the Union Oil Co. California. similar experiment very scale was tried out for magnesium dust slurries the high tension laboratories Stanford University. The author warned the plant manage- ment many occasions that would great risk process industry install plant full size pacity without going through pilot stage. But all warnings were vain, and second unit was built use the method, given the author Raden- thein, 1933, entirely uneco- and difficult operate. far present information goes, the second unit with the hydrocarbon oil chilling was complete failure, and was necessary rebuild the plant using the gas chilling method accord- ing the old design the No. unit. Fig. and retort furnace battery Konan. Capacity here was 5000 day. The analytical investigation the magnesium dust produced Per- manente shows lower magnesium content and higher carbon content than the dust produced Raden- and Konan. The author has not been informed whether the careful raw material balance and gas bal- ance, proposed him, has ever been made, decide whether using natural gas chilling agent causes less efficient prevention the back reac- tion, whether the dust diluted carbon resulting: from partial cracking the methane, whether incomplete reaction the furnace has taken place using graphitic type reduction carbon against anthracite. There are several questions un- solved, as, for example, the influence the raw material; Konan uses dead-burned natural magnesite con- taining iron oxide, whereas, Per- manente, only iron-free magnesia used from sea water precipitation process. important investigate all these questions that mag- nesium dust may produced which tablets easily the dust produced Radenthein, Konan, and Swansea. long any hydrocarbons are used the carbothermal reduction proc- ess, the author very doubtful that magnesium can produced price competitive with process. The carbothermal reduction process has been dealt with detail, the author has had special experience its development, and the larg- est installation for thermal reduc- tion process the But carbon not the only agent which can used for the reduction magnesium compounds. Other reducing agents exist which have the great distinction producing oxides which, the re- duction temperature, are not the gaseous state, that only magnesium vapor delivered such reduction processes. The oxide formed the reducing agent remains solid liquid form the reduction chamber. such cases the magnesium con- stantly removed from the other com- ponents, forming system the equilibrium state, and therefore such reactions can proceed the end; also back reaction possible, the magnesium has already separated from the other components. looks, therefore, first glance, such processes can operated more simply, special means chill- ing are necessary recover the mag- nesium. Such reducing agents are alumi- num, silicon, and calcium carbide. The main difficulty that all the above mentioned reducing agents are very expensive comparison with carbon, that the economy these processes still remains doubtful, un- less special arrangements and local conditions influence the economy their advantage. The oldest these processes operated commercial scale was the reduction magnesium oxide with calcium carbide. This pro- ceeds according the THE IRON AGE, November 25, | 4 | Murex Co. England used this process could import calcium carbide very easily from Norway. The calcium carbide finely ground to- gether with the magnesium oxide, and the powdered mass tableted without binder. These tablets are heated un- der high vacuum retort tem- perature 1800 deg. The mag- nesium evaporates and condences the cooler part the retort the form solid ring. This process has been operated since 1936 from small retorts, and the metal was recovered batches. When the author arrived fornia June, 1940, got con- tact with Marine Magnesium Prod- ucts Corp. South San Francisco. had long planned use magnesia recovered precipitation from sea water for the carbothermal reduction process. The idea using sea water source for metallic magnesium goes back 1936, when the author, Korea, began corresponding with Marine Magnesium Products Corp., study this possibility. This company has done pioneering work solving the problem extracting magnesium compounds from sea water for phar- maceutical uses. The precipitation the magnesium compounds consists mainly reacting lime slurry with sea water Dorr thickener. exchange ions takes place. The magnesium chloride contained sea 56—THE IRON AGE, November 25, 1943 water forms magnesium hydroxide, which precipitated, calcium chloride going into solution the sea water. lime carry out this process econom- ically. any case, magnesium droxide first precipitated from the sea water, and depends the sub- sequent process selected whether the magnesium oxide, whether mag- nesium made from such oxide the carbothermal any other ther- mal reduction process, whether the magnesium hydroxide dissolved hydrochloric acid make, finally, an- hydrous magnesium starting material for the electrolytic process. lime necessary for the precipi- tation magnesium hydroxide from sea water, the writer conceived the idea combining the calcium carbide reduction process with the magnesium sea ‘water. The above mentioned equation the reduction magnesium oxide with calcium carbides shows that residue remains consisting calcium oxide and carbon. the reduction with calcium carbide out reaction between solids, none the components this equation melting 1800 deg. Such reactions are al- ways incomplete and therefore the residue contains additional unreacted station the Permanente plant, for filling magne- sium dust paste into re- torts. calcium carbide and magnesium oxide, which all goes waste and reduces the economy the calcium carbide reduction process. this residue slaked with water, then the unreacted calcium carbide and the calcium oxide form calcium hydroxide (lime slurry) accompanied the carbon residue from the decomposition. Such slurry re- acts just the same pure lime slurry with sea water, the calcium hydroxide going into solution calcium chlo- ride, and the magnesium chloride the sea water precipitating mag- nesium hydroxide. The only differ- ence that the magnesium hydroxide contains the carbon from the carbide. This advantage the settling rate the magnesium hydroxide pre- cipitated from the sea water higher with the carbon content than without it, which fact reduces the Dorr thick- ener installation, and finally, the car- bon acts additional fuel during the calcination process produce magnesium oxide from the hydroxide. The great economic feature this combination consists that the lime first used make calcium carbide, and after the magnesium reduction, the lime contained the residue later used precipitate new mag- nesium hydroxide from sea water. can said that for this combina- tion only lime and coke and sea water are necessary produce the metal. = ‘ ‘ ‘ station nente nagne- oxide, educes water, panied the rry re- chlo- ride mag- differ- droxide settling pre- higher without car- during produce this lime carbide, duction, sidue ater. ombina- water metal. This process protected several patent applications taken the name the author and assigned Marine Magnesium Products Corp. The difficulty the whole calcium carbide reduction process p