The Iron Age 1944-06-08: Vol 153 Iss 24

President and Editorial Director BAUR Vice-President General Manager ° ° ° Editorial and Advertising Offices 100 East 42nd St., New York N.Y., U.S.A. 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 428 Park Philadelphia Chicago Chilton 1134 Otis 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 Vice-President GEORGE GRIFFITHS EVERIT TERHUNE Vice-President VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE THOMAS KANE HARRY DUFFY CHARLES HEALE ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Subscription North America, South America and Possessions, $8; Foreign, year. Single Copy, cents. ° ° ° Cable Address, Y." ° ° Copyright, 1944, Chilton Company The IRON AGE Vol. 153, No. June 1944 Editorial Transom Business and Ten Percenters Technical Articles Alumino-Silicate Refractories Carbide Wear Rings Prowling Core Box Life Forging Ferrous and Non-Ferrous Metals Silver Solder Broken Press Frame Casting Redesigned Welded Steel Sheet Fractures Detected with Supersonics Controlling Machineability Screw Machine Stock Grinding Lead Screws Hot Pressing and Sintering Carbide Powders New Equipment Features News Front Assembly Line Washington West Coast Personals and Obituaries Fatigue Cracks Dear Editor This Industrial Week News Industry News and Markets Basic Metals Near Balance Surplus Aircraft Disposal Venezuelan Ore Developments Plant Expansion Continues Steel Wage Hearing Commercial Aspects Steel Industry British Plan Public Steel Ownership Developments Rocket Guns Budd Predicts Rail Expansion Non-Ferrous Metals News and Developments. Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Finished Iron and Steel Steel and Warehouse Prices Semi-Finished and Tool Steel Prices Steel Pipe and Tubing Prices Wire Product Prices Pig Iron and Coke Prices Railroad Material and Stainless Steel Prices Ferroalloy Prices Index Advertisers 100 105 108 109 116 132 134 135 136 138 139 140 141 142 143 144 145 146 ° ° ° ° ° ° ‘ ° ° ° 205 Firth-Sterling, long specialists making steels for shop tooling, early recognized the possibilities carbides means extending the improvement shop practice brought about the super high- speed steel—CIRCLE But, there place Where the highest speeds are obtainable ma- terials are hardest, FIRTHITE the “last word” ten times those possible with high-speed steels. Where speeds above average are permissible materials are the hard CIRCLE cut least 25% faster than ordinary grades high-speed steel. Send for descriptive literature these remarkable materials. 4 44—THE IRON AGE, June 1944 STEEL COMPANY For instance: FIRTHITE removes 730 pounds gray-iron cast- ing metal per hour instead 180 pounds; 4 minutes instead hour; enables milling-cutters run 1,000 feet per minute instead 100 feet with previous ma- terials. 9 For instance: CIRCLE machines hard die blocks hours instead hours ... doubling tween grinds versus regular high-speed steel; pieces treated alloy steel between grinds than speed steels. turns two to more HERE ARE PLACES FOR BOTH AGE ESTABLISHED 1855 ° ° June 1944 VAN DEVENTER President and Editorial BAUR Vice-President and Manager ° ° DIX Manager, Reader Service ° Editorial Staff OLIVER Associate Editors WINTERS BARMASEL Editorial Assistants SCHIEN WILLIAMS ROGERS CAMPBELL Pittsburgh 428 Park POST Chicago 1134 Otis Bldg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press MacDONALD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Angeles JOHN McCUNE Birmingham ROY EDMONDS JAMES DOUGLAS Transom Business and Ten Per Centers A’S rich and doesn’t care.” That thought has “busted” more promising careers than has most the causes failure, that one meets with between the cradle and the grave. You have heard surely the phrase concerning hard and easy money. Money always hard for most people get; easy for some people spend. People who get their money the hard way usually not get into bad habits. They can’t afford to. Government gets its money the easy way. Its income not measured the values that creates but the tax bills that passes. When needs more, demands and gets it, regardless any thought econ- omy. Today, when Government income has swelled astronomical figures, perspectives have been almost obliterated and the thought economy expenditures like the man who wasn’t there. Per- haps that’s the way has win war. But this torrential outpouring easy money that was the first instance hard money get has overflowed its legitimate banks and psy- chologically dampened certain managerial minds industry and busi- ness. The easy money psychosis not sound approach the necessi- ties the postwar realities which will again demand the hard money concept. That why doing some thinking and talking about transom business and ten per centers. good many concerns, ourselves included, are today getting busi- ness “over the transom” from concerns that have never dealt with perhaps even heard of. like think that this the reward merit afforded superior product. But there possibility that some measure least choice.” Today people will take what they can get and like it. Transom business business that you haven’t sold. has been bought the customer without footwork and personal contact your part. course reputation, advertising and conditions have helped but unless you can put your finger the predominant factor your sales job these cases not finished but only begun. Transoms are not one way openings and business can float out them well through them. Sales management today should concentrate clinching the tran- som business. Your salesmen have more time that today than they will have the postwar tomorrow. Akin this and bred the same extravagant parents the ten per cent psychosis. affects some people who are charge the spending company funds when they are the excess corporate tax bracket. spend dollar,” they say, “it only costs the company ten cents.” Laying aside the thought that excess profit taxes are contributing large measure help win the war and end quickly possible with the least sacrifice human lives, there another angle con- sider. When executive kisses economy goodbye and says: have little use for you today,” she will return him when needed only with reluctant feet and after much persuasion. And will take time make her believe that means what says. | | | | - | | | | ! | | | | | | | | | | 7 June Longitudinal bod seams are clamped before Bri ance welding. for nat Pos Barring increas Dev with Powder boxes period. powder dry. For steel thread: Mal How the Navy Keeps Its Powder Dry Stored deep the holds fighting ships Tops and bottoms are made 13-ga. sheets. The are water-tight boxes—each containing tops are formed four operations—blank and powder. These powder boxes punch opening, deep draw and emboss stand hard usage, stack easily and keep precious trim corners and roll back edges. The powder condition for instant use our qualities Inland sheets fighting men. Thousands have been made help speed production and save time and Inland hot-rolled pickled and oiled sheets. materials. They are welded construction, and galvan- When Victory ours, the modern Inland ized inside and outside for full protection. The continuous sheet and strip mills, which now are opening the top sealed with gasket drawn producing full capacity for the war will again making sheet and strip \ bodies are formed from 16-ga. sheets. for hundreds peacetime products. INLAND STEEL COMPANY South Dearborn Street, Chicago Illinois Cincinnati Detroit Kansas City Milwaukee New York St. Paul under tight hand screw and spider. The kept produc airers > T nus! hip’; News June 1944 British trade unionists the Iron and Steel Trades Confederation have asked for nationalization the iron and steel industry from the smelting pig iron the manufacture the finished products the industry. Postwar prosperity has been predicted for the scrap industry Barringer. Lasting two five years, demand for iron and steel scrap will increase after short reconversion period following the war. Development work Bethlehem hematitle mines Venezuela has already begun with two million tons iron ore expected annually the end the construction period. For the location intercrystalline fractures parallel the surface steel sheets. German metallurgists have turned supersonic equipment. Supersonic waves meeting air cavity are reflected. receiver arranged the other side the sheet being tested, waves detected all points where they have traversed uninterrupted path. Tool orders for the current heavy shell program are about completed, but the volume has not approached the $250 million orders promised the military. Wachines yet ordered include multi-spindle automatics for fuse work and nose threading machines and chasers. Makers industrial power trucks are making experimental models with WPB blessing, that postwar equipment needs can estimated. The ore industry sees hope OPA move the direction increased prices until decision reached the steel wage case. The most interesting American fighter plane, which shortly will reach the fighting front, the Northrup Black Widow. Details the plane have been kept quite secret. It's job, which unusual that the only other plane the American and the Germans have ceased production their fighter. The Black Widow heavily armed with guns firing both forward and the rear, fitted with tricycle landing gear, and has two Pratt Whitney motors, presumably 2200 hp. The Boeing B-29 super flying fortress, which has for some time been full production, has acquired the nickname the "Tokyo Bomber". building air force purchasing interned military aircraft which have been forced down the Irish Free State. The force consists number British types, some German Heinkels and some American Grummans and Lockheeds. "The Wild Sow" not new German airplane, which has been reported, but rather new attack technique. This new method "attack any cost", and while does get some Allied bombers the German pilot losses are severe. Col. Hermann, Inspector the German Air Defences, has said that the new attack method has resulted in, "losses substantial numbers outstanding, and highly decorated officers and commanders air units." Sappington, industrial health consultant Chicago, produced the conclusion that can per cent the jobs ordinarily performed men. Also concluded was that women had earned permanent places industry. outstanding health problems were found among women workers, although they bothered small ills and visited plant dispensaries more frequently than The developer the jet airplane, Group Captain Whittle, has transferred, payment, the whole his financial interest Power Jets, Ltd., the British Government. will continue direct the work the company. And: The development the British jet airplane being transferred Canada for extensive experimental work, with emphasis testing the jet motors under cold weather conditions. COM . | +. ¥ | ‘ aa 7 « ~ ‘ é ‘ : é © k 4 . Continuing his series reports steel plant refractories, the author, the first two articles, describes those having composi- tions between that siliceous fireclay brick (about per cent and pure alumina. Their chemical composition, physical structure, properties and world distribution are herein discussed. ° ° fact that Research Department, United Scherrer ray Steel Ltd., Stocksbridge, England photographs. “firebrick” gen- erally mean brick, not any other kind refractory trib- ute the unique position held this class material. with fireclay bricks other alumino-silicates varying from pure silica pure alumina are included, the range refractories comprehensive that can used meet the whole requirements the acid open hearth furnaces, reheating furnaces and the casting pit. (1) Clay: Wilson defines clays as. “the weathered products silicate rocks, containing sufficient hydrosili- alumina the softened con- dition produce plastic semi- plastic mass when tempered with water.” Although this definition quite adequate for ordinary purposes, clay now known very much more complex material than was once thought. big step forward was taken when was realized that known once and various impurities such mica, feldspar, and quartz. has since been shown that this “clayite” usually consists the mineral kaolinite, but that other minerals similar chemical composi- tion may also present for example, nacrite and dickite, together with quite different minerals the montmorillonite and illite types. That these materials are not identical with kaolinite (the main constituent china clay) 48—THE IRON AGE, June 1944 Bragg his book the “Atomic Struc- ture suggests that the exploration this fascinating field has only just com- menced. states that general characteristic the clay minerals the presence single sheets linked tetrahedral (Si-O) groups similar the double sheets present the mica type minerals where aluminum magnesium acts bond. The crys- tals are small that they are recognizable even under the most powerful microscope but they ean identified X-ray “powder” methods. Quite recently, further ad- vance has been made the use the electron microscope. With magnifications one hundred thousand diameters the diameter, shape, size and characteristic crystal habit clays have been studied shown very strikingly the photo- graphs reproduced Fig. These are taken from recent paper the American Ceramic Society Humbert the Department Agronomy, Ohio State University. The photographs show that the postulated differences crystal size and shape the various clay minerals are very real and that way surprising that the clays themselves should have different physical prop- erties. similar examination ben- tonite (not shown Fig. reveals that each unit composed aggre- gates extremely thin, plate-shaped The extreme thinness the plates and the large number wate: films, help explain the high plas- ticity this material, while the big surface area responsible for the high bonding power and high drying shrinkage bentonitic clays. Such clays, which fall the gen- eral classification montmorillonite are principally used bonds foun- dries. They also find considerable application the steel plant, for ex- ample bond for such refractories Montmorillonite and illite mica-like mineral) are also found minor constituents some fireclays where they serve increase the plasticity very considerably. Hauser his Edward Orton Memorial Lecture the Americar Ceramic Society 1941 gave de- tailed description the fundamental properties the clay minerals. stated that the ultimate clay crystal negative charge either absorption anions its surface, because unbalanced crystal lattice. result has the ability absorb certain number cations balance its charge. When the clay suspended water these will dis- sociate distance which depends their valence and hydration. The entire clay micelle may, therefore, compared with dissociated electro- lyte. Just sodium soap will ex- change its sodium for the hard water the cation the clay may exchanged for another one. This phenomenon, known “base exchange,” although apparently far removed from the every day life the steel plant, has fact direct bearing such important questions the workability cements and the density fireclay blocks. Hauser states, “it big step from the work- ing out the properties all the minerals that may found clay the application this knowledge the production improved refrac- tories, but only when this has been done that shall exchange the present method working with ill- defined heterogeneous mixtures valen are basic terna lonite withi and Jay rang clays all proac i f | layer ture has X-ra firing gra eral tice clays and praying that things will all right for truly scientific ap- proach.” Fig. taken from recent paper layer kaolinite crystal. The free valencies the edges the layer are shown have taken various kaolin these replaceable basic ions are only present the ex- ternal surface but the montmoril- lonite clays the magnesium atoms within the lattice can also replaced and hence much higher base ex- change capacity possible. Another aspect which research clay has recently made rapid progress that the changes which when clays are heated. Thus, Jay has X-rayed number clays, ranging from the siliceous the alu- minous, after firing the tempera- ture range 1652 2552 deg. and has come the following conclusions: (a) Quartz siliceous clays begins eonvert cristobalite about 2012 deg and not usually observable the X-ray pattern after the 2372 deg. firing. (b) Gamma alumina present Electron microscope photo- graphs clay min- erals the lat- tice type (after Humbert). A—Kao- B—Dickite; Halloysite; Sciotoville E—Attapulgite; Ball Clay. Unit measurement in.) temperatures between 1652 deg. and 1832 deg. not observed 2012 deg. over. (c) Cristobalite first observed 2012 deg. formed, for the most part, from free silica from the dissociated clay higher temperatures, 2372 deg. 2552 deg. F., cristobalite tends disap- pear with the appearance diffused reflection suggestive glassy material. (d) Mullite first observed 2012 deg. There does not appear any marked increase the amount with in- creasing firing temperature. however, distinct crystal development after the 2552 deg. firing indicated the sharpness the line pattern, especially for the high order reflections. The presence mullite fireclay brick has been known for long time but only comparatively recently that Birch (in collaboration with Taylor Pennsylvania State College) that the mullite was present com- paratively low temperature and was the size the crystals rather than their concentration which increased with the firing temperature. They decided that all the mullite that would form was al- ready present the specimen after firing cone TT. For long time was thought that the needle-like crystals formed hard-fired fireclay and porcelain prod- ucts were the mineral sillimanite now, however, gen- erally agreed that these crystals are distinct mineral, mullite, having composition and far only discovered nature the Island Mull, Scotland. ordinary fire- bricks the crystals are too small identified under microscope but when the bricks have been subjected slag attack the crystals grow and may visible even the naked eye. thin section through such slagged crucible ing that the intermeshing these minute crystals fireclay brick strength. (2) Andalusite, Sillimanite, and Kyanite: These minerals which occur considerable quantities nature and are all employed refractories have similar, though far from iden- tical, properties. Their optical char- acteristics are compared Table with those mullite. The properties ta d 4 THE IRON AGE, June 2—Edge Si-O layer kaolinite crystal vertical projection showing cations bound free valencies (after Endell). mullite and sillimanite are sim- ilar that not surprising that there has been some confusion when only poorly developed crystals (often embedded glass) could com- pared. All three these very refrac- tory alumino-silicates break down heating give mullite and excess silica. (3) Corundum The other important mineral the present series corundum. formed when precipitated alumina various aluminium salts were heated sufficiently high temperature. has higher refractive index (1.759 1.767) than the above minerals, col- orless and usually occurs euhedral has weak birefringence with maximum interference color the second order and extinguishes parallel the crystal outline. found nature but most the formed electrical fusion bauxite, rock consisting essentially hy- TABLE Optical Properties Alumino-Silicates drated alumina minerals. Diaspore also used for increas- ing the alumina content alumino- silicate refractories. Reactions With Other Oxides This system, (Fig. 4), which was first worked out Bowen and Greig, provides fundamental data the whole range alumino-sili- shows the general influence com- position melting point. Thus, bricks approximately 100 per cent silica content should have melting point about 3092 deg. but even small addition per cent) alu- mina will result serious drop refractoriness. Beyond this the refrac- toriness will tend increase again with the alumina content. should, however, pointed out that fireclay bricks are not equilibrium products the alumina-silica system and that, quite apart from the presence im- purities, other factors such the fir- ing treatment must considered. Two instances will suffice show the danger rash generalizations the basis the alumina-silica dia- gram; the first the acid induction furnace where china clay added ganister gives much more durable (and quite refractory) patch than straight ganister. The other the acid bessemer where addition per cent quartz per cent alumina tuyeres was found give improved life. both cases even the slagged product far from brium, the reaction products contain- ing large pieces quartz that have not even had time convert cris- tobalite. such cases, the problem (Data abstracted from Section Rogers and Kerr, McGraw Hill Book Co., Inc., Mullite Andalusite Sillimanite Kyanite Refractive indices. 1.642 1.654 1.632 1.643 1.659 1.680 1.712 1.728 colorless usually colorless colorless pale blue Long prismatic habit Euhedral crystals Slender prismatic Broad elongated plates— with nearly square course columnar aggre- crystals—felted mass tabular 100. cross-section gates. Cross-section fibers. nearly square. Moderate. First order Moderate. First order Rather strong. Moderate. yellow, maximum. maximum. 2nd order blue. order red. Extinetion.......... Parallel longitudinal Parallel most Parallel 100 about deg. sections. sections. with length crystals. Occurrence Island Mull common mineral. metamorphic rocks. metamorphic rocks. 50—THE IRON AGE, June 1944 side. (5) the brick: FeO been paper study whick show! two that. reduc grade 2192 work mills nite tures know terna syste mang the lite ment \ \ \ \ \ rather one two refractories— fireclay and silica—being used side side. Information the fundamental reactions fireclay bricks with other oxides, notably FeO and the steelworks, has been greatly enhanced two recent papers, the first Snow and Mc- Caughey, and the second Snow. Still more recently Schairer has con- sidered this system part wider study the quaternary The equilibrium diagrams which they have worked out are shown Figs. From the first two these figures will seen that. the addition iron oxide even the amount only per cent reduces the melting point high grade fireclay material low 2192 deg. Further additions result slag which likely very fluid working temperature. Those who have had experience millscale fireclay even sillima- nite hearths operating tempera- tures 2192 deg. 2552 deg. will know how serious this reaction can ternary compound reported this system although two are reported the corresponding system containing manganous oxide. The only binary compounds which have been found are lite and mullite. The diagram particularly valuable shows that only slight improve- ment resistance FeO attack likely with small increase Mullite needles formed melting iron with ad- ditions manganese and aluminum fireclay crucible. the alumina content fireclay brick. With much higher alumina contents, approaching that itself, much increased resistance, al- most comparable with that mag- nesia, obtained. (6) This system many ways similar that the corresponding system containing FeO, the low melting point region occur- ring approximately the same part the diagram. Two ternary com- pounds tite) and have, however, found. The first these member the Garnett family and was previously known nature but the second does not ap- pear have been noted except these synthetic melts. with the FeO diagram, any in- crease alumina above the clay composition results increased resistance MnO, but the rate rise slow compared with that which the price the refractory in- creases. not surprising, there- fore, which un- has higher resistance attack FeO and rich slags than the ordinary fireclay brick, has not met with any wide application steel plants. (7) This system, which was first worked out Rankin and later modified Properties Selected American Alumino-Silicate Refractories TABLE Intermediate Heat Duty Per Cent PerCent Per Cent Heat Duty Duty Regular Alumina Approximate deg. F............. 3029 3133 3184 3241 3299 3335 Density (bulk). grams per 2.114 2.082 2.323 2.082 2.178 2.082 2.659 Spalling loss—per cent: Reheat Test—Change—Linear Load Test—25 Ib. per sq. in. for hr. per cent subsidence: THE IRON AGE, June other flint clays which get their name from 2000 their characteristic structure and ap- ing pearance. Clays are also mined for after 1900 Silica system show- refractory purposes New Jersey, The ing the general in- Texas, Mississippi, California, Wash- fluence composi- ington and Colorado. the Ozark region Missouri clays varying from plastic not prod- diaspore are found and these are clay Corundum ucts and therefore particular value the manufac- The must considered Great Britain the clays are also Greig). facturing such products are found tal Per cent weight most refractory products come from nary and less extent from quartz Cornwall the form china clay Bowen and Greig, principally adopted for steel works, presumably Clays with refractoriness for interest connection with blast fur- because the resulting drop high 3146 deg. 3182 deg. effect nace work. shows that here again the product. From the users’ standpoint the but great improvement performance great deal more work required can roughly divided into fect can expected small increase before the reactions alumina-silica three groups according their alu- which the alumina content above the with other oxides can content. The normal fireclay present in kaolin. It 1S doubtless of predicted, even for equilibrium eondi- brick has an alumina content of be- ties Si importance also connection with tions. particular the quaternary tween and per cent, but siliceous basic open hearth slags but here the diagram requires pricks with low per cent Alkali reactions are complicated the working out and the quinternary are used. The best Scotch fire- impor presence number other oxides. formed these oxides with lime. brick and the high duty and super ent (8) This system Given this information more fun- duty firebricks used America have direct interest the damental approach would much higher alumina content and per steel plant since explains why many steel plant problems. correspondingly higher refractoriness. must the use magnesite brick con- Great Britain, relatively few bricks tact with fireclay brick high Raw Materials are manufactured the temperature leads serious fluxing. Fireclays suitable for use the tween per cent alumina and the has been suggested that cordierite manufacture refractory bricks are per cent alumina “silli- bond for casting pit refractories states. particular they are found however, the existence the diaspore and would increase their thermal shock resistance. That does shown the good results obtained adding pottery saggers. and mined Illinois, Indiana, Ken- tucky, Maryland, Missouri, Ohio and Pennsylvania. They are often asso- ciated with coal measures and may clays enables continuous range products made. Although the initial selection refractory clay generally made the basis The idea has not, however, the plastic type the so-called chemical analysis refractoriness, amoul TABLE mater rubbi Selected British Alumino-Silicate Bricks Sillimanite Medium Per Cent |(62PerCent Per Cent Per Cent accon Alumina Kaolin Alumina A1203) Alumina Alumina Apparent porosity, per 30.6 19.4 24.0 16.4 23.8 24.9 26.2 the Bulk density gram per cc.. 1.85 2.08 2.00 2.08 2.33 2.62 2.90 Apparent specific gravity........ 2.67 2.59 2.63 2.48 3.06 3.48 3.93 Cold crushing per sq. in. Full brick end. 1940 2500 4890 6050 Over 8300 7380 cover 2h—2570 deg. F.. 6.5 exp 0.0 0.0 sq. in. rising temperature: Initial 1150 1500 1340 1300 1500 1560 1340 the Rapid 1270 1550 1570 1540 1580 1580 1560 Shear 1410 1600 1630 1610 1760 1690 1700 Therma! shock 30+ 30+ 30+ 30+ 30+ 30+ 52—THE IRON AGE, June 1944 i | other properties are, course, im- portant, for example, plasticity, dry- ing shrinkage, firing shrinkage, and after contraction the fired bricks. The desired state often achieved mixing number clays. Thus, America the flint clays and the plastic clays are employed together with certain amount pre-calcined clay brick the so-called “grog.” The amount grog added varies ac- cording the process from per cent over but general between and per cent the to- tal batch weight. The principal impurities ordi- nary fireclay are silica (as raw quartz) and iron oxide. The presence silica excess that required for the kaolinite ratio has lowering effect the ultimate refractoriness but much more important the ef- fect iron oxide, few per cent which may lower the melting point ties such titanium oxide, lime and magnesia have less marked effects. Alkalies, the other hand, are very important. They are generally pres- ent the extent less than per cent but clays with recent high per cent alkalies are known and must avoided for refractory pur- poses. The specific effect the al- kali will discussed more detail later this article, will also the effect carbonaceous material. Andalusite principally found Chesters steel plant refrac- tories, that have appeared THE IRON AGE are: Open Hearth Fur- naces,” Aug. and 22, 1940. “Steel Plant Refractories,” Feb. and 13, 1941. “Basic Open Hearth Above Sill Plate Level,” May and 29, 1941. “Basic Open Hearth,” Aug. and 21, 1941. “Casting Pit Refractories,” Nov. and 27, 1941. “Electric Steel Plant Refrac- tories,” March and 12, 1942. “Acid Open Hearth Refracto- ries,” May and June 1942. “Soaking Pit and Reheating Furnace Refractories,” July and 23, 1942. “Acid and Basic Bessemer Refractories,” Nov. and 12, “Silica and Semi-Silica Re- fractories,” Jan. and 28, 1943. “Magnesite Refractories,” June and 10, 1943. “Dolomite Refractories,” Aug. and 12, 1943. “Chrome Ore and Chrome Magnesite,” Nov. and 18, 1943. America White Mountain, Cal., but also mined lesser extent Nevada. Sillimanite principally found the large deposits the Khasi Hills Assam and Pipra, Rewa In- dia. These deposits are rather inac- cessible and yet are relatively undeveloped but will doubtless yield increasing quantities sillimanite the demand increases. Kyanite also occurs commercial quantities, principally North Caro- lina. also found Imperial County, Cal., and amounts India. The development kyanite refractories and the use topaz alternative material fully discussed recent article McVay and Wilson. (See bibliog- raphy.) Corundum mined some extent but the greater part the alumina used for high alumina refractories comes from the calcination elec- trical fusion two hydrated alumina minerals: Bauxite and Al- though bauxite found all over the world the important deposits are mainly the hands Russia, France, United States, Dutch Guiana, British Guiana, Hungary, Italy and Yugoslavia. Minor quantities are found other countries for exam- ple Greece and Northern Ireland. This peculiar distribution is, however, more important the aluminium industry since the refrac- tory trade can draw the diaspore deposit Missouri both for the manufacture bricks and cements. Editor’s Note: The discussion con- cluded next week with description the manufacture, properties and applica- tion alumino-silicate refractories. Carbide Wear Rings Prolong Core Box Life RECENT example the sav- ings which can effected the substitution -of small amount tungsten carbide for other materials exposed wear (caused rubbing abrasion) comes from Ohio foundry. aluminum core boxes—made halves and held to- gether clamps—are used. (See accompanying sketch.) After box has been filled with core sand and sand rammed down into the box, the box rubbed over the bench top smooth off the bottom. The rubbing over the bench top covered with highly abrasive core sand wore away the bottom the boxes unevenly. This put such strain the dowel pins used line the two halves the core box that time the box had scrapped overhauled, the life the average aluminum core box being only about 1500 cores. The foundry secured from Car- boloy Co., Inc., some cemented car- bide fishpole guide rings originally made withstand the wearing ac- tion fishing wire fishline. These rings were attached the bottoms the core boxes that the hard abra- sion-resisting rings, rather than the comparatively soft aluminum take the SPLIT TWO HALVES brunt when the boxes are slid along. The result has been big saving time previously lost while repair- ing the boxes making new ones, since the carbide wear-proofed boxes produce 9000 more cores before overhauling becomes necessary NOTE: CORE BOX HALVES HELD TOGETHER BY CLAMP WHICH IS NOT SHOWN THE IRON AGE, June 1944—53 1 n e - q Ss hee a OPERATION \\ BOARD and Aircraft engineers the necessity using forgings for parts which must withstand terrific stresses has acquainted many manu- facturers with their qualities and ad- vantages. Government contracts specifying drop forgings have made necessary the purchase forgings many contractors and sub-contrac- tors who previously had little idea the processing facilities re- quired for their production. For the guidance these new users might well explain the different classes forgings and the methods pro- ducing them. Closed die forgings die produc- tion forgings are produced impres- sion dies, each which commer- cial duplicate the other. Their fabrication may conducted steam, air board drop hammer, up- set forging machine, forging press 54—THE IRON AGE, June 1944 ORGING alu- minum alloy pro- This closed die, with ex- cess metal being forced out into the the die impression. combination any these for the production the intricate more complex designs. Closed die forgings produced hammering steam, air board drop hammer are further classified and termed drop forgings. When the metal displaced the application pressure the forgings are termed upset forgings press forgings, de- pending upon whether the equipment used was upset machine forging press. There are many applications for forgings wherein the quantities produced are too small justify the expense sinking impressions the dies. Such forgings are made flat dies with the use hand tools and are known flat die forgings, plain hammer forgings blacksmith forg- ings. Forgings this class are pro- duced steam hammers hydraulic presses and are only rough duplicates each other, requiring greater di- elopments THOMPSON Sales Engineer, Transue Williams Steel Forging Corp. mensional tolerances and more ma- chining than closed die addition the production small quantity lots flat die forgings, this method used both for parts which are such shape that closed dies are impractical and also for the produc- tion large and extremely heavy forgings. The hammer equipment for produc- ing flat die forgings while having the same general principle operation designed give wide work- ing area which necessary for this class production. The hammers are the double frame single frame type and will produce forgings weigh- ing several tons. The presses are generally used for extremely heavy forgings, cogging down ingots, pro- duction die blocks, large gun bar- rels, marine engine crankshafts, ete. designing parts for closed die forging, the engineer cautioned utilize the inherent grain fibers the highest physical properties. Adequate filets, ample radii and sufficient draft angles are essential for high rate forging production and for pro- longing die life. These details de- sign help relieve one the major bottlenecks the forging industry reducing the frequency re-working dies. Also these good designing fea- tures tend decrease the cost forgings. The selection method for pro- ducing closed die forgings usually matter for the decision the forg- ing engineer. The type metal, shape and weight the part and the avail- able equipment are carefully consid- ered the selection the forging process. There are cases where the same part produced press forging one forge shop and board steam hammer forging anoth mach hamn all from ing ings use | havil sive desig type: may chine forg tion, well chin upse dian forg end tion the num rolls met rolli sect Alu soli bar: blac and has lem wit orging another. Likewise certain design might forged upset forging machine one plant and steam hammer another. was mentioned earlier that not all forging designs can produced from one set dies single forg- ing unit. Generally closed die forg- ings 200 lb. and over require the use two more hammers, each having dies made with the progres- sive tooling required complete the design. Some forgings may require combination two more different types forging equipment which may include forging press, hammer, forging rolls and upset forging ma- chine. The following are common ex- amples the use the drop forging hammer combined. with other types forging equipment. The bracket used mount the engine the B-26 bomber forged and then upset forging machine form cup sec- tion, thereby reducing the weight well eliminating expensive ma- chining operation. Camshafts are first upset gather stock for larger diameter gear section before being forged under the hammer. The flange end crankshaft formed up- setting after hammer forged. order obtain excellent condi- tion grain fibers connecting rods, the billets are passed through number impressions the forging rolls obtain proper blank which then finished the hammer. One method producing axle shifts rolling the tapered section forging rolls and then upsetting the flange section the upset forging machine. Aluminum propeller blades the solid type are produced rolling the bars forging rolls, flattening the blade end preparatory forging 35,000 Ib. hammer. After forging and removal the flash, the hub end heated, bearing rings put on, and then upset 5-in. upset forging machine, The fabrication propeller blades has presented some very difficult prob- lems the engineer who must keep within weight limitations and still at- tain high physical qualities. With de- Ferrous and Non-Ferrous Metals The rapid rise the use both ferrous and non-ferrous forg- ings has resulted many new production problems. guide these new comers this field, the author explains the different classes forgings and describes methods for producing them. mands greater horsepower and faster speeds there have been least six methods developed for the produc- tion this item. Besides the solid aluminum blade design some propel- lers are produced encasing light webbed steel forging within welded steel covering. Hollow steel blades chrome-nickel-molybdenum are made using welded plate and forging construction, heat treated high degree strength and tough- ness. Other methods developed for producing hollow blades are roll- ing automatic mill equipment and forming seamless steel tubing. Forgings Aircraft Closed die forgings have been the answer the aeronautical engineer’s problems providing strength with minimum weight the engine well the wing and fuselage assembly bombers and fighters. Controlled grain flow and proper distribution metal heat treated forgings have made possible reduce the engine weight slightly less than one Ib. per hp. Crank cases for radial aircraft en- gines are forged from either alumi- num alloy steel. The same method used for both metals except that aluminum requires hammer operation and press for cogging down the ingot 9-in. square billet, whereas steel rolled this size and furnished the forger from the steel mill. The production steel crank case sections accomplished hammer upsetting the 9-in. square billet, and saw cutting the proper weight form the blocked rough forging. For this operation the billets type AMS steel are heated for hr. Hagan oil fired rotary furnace ata temperature 2250 deg. After blocking 35,000 lb. Erie steam hammer the forging trimmed, the center punched out and returned another rotary furnace for reheating preparatory finish forging. The rough forging finished 25,000 lb. Chambersburg steam hammer, again trimmed and punched, and then annealed cycle controlled con- tinuous annealing furnace. After an- nealing, the crank case sections are rough machined, and then heated ina rotary furnace 1525 deg. for oil quenching. The quench tank the ferris wheel type with temperature control the coolant and designed discharge quenched forging each time hot forging placed the tank. The drawing tempering oper- ation conducted Ro-To-Air furnace controlled 1210 deg. may interesting know that the finish machined crank case forged from alloy steel less weight than the finished aluminum forging. Propeller hubs and master connect- ing rods are drop forged from SAE- X4340 steel with prolongations each forging for inspection struc- ture and physical properties. The front and rear crankshafts for radial engines are forged from type SAE- X4340 and SAE-2512 steel. These also have prolongations forged integrally with the piece for use quality check the forging. Formerly tensile test was made from each pro- longation master rods and crank- shafts, but with desire conserve steel which possible due qual- ity and uniformity forging processing, one engine manufacturer has changed the specifications fracture test each prolongation and one tensile represent quantity lot forgings. The use forgings aircraft con- struction not always due de- sire reduce weight. not un- THE IRON AGE, June 1944—55 C- lie lly id- common for engineer change from castings forging designs be- cause lower machining costs, elim- ination welding, reduction in- spection time and reduction rejects and scrap losses. The tail wheel fighter plane and the yoke used the retractable landing gear have been redesigned die forgings one company for these advantages. The inspection record one aircraft builder shows that the use sup- port forging which was formerly casting has eliminated tions entirely. Scrap losses, which were previously per cent, presented inestimable expense due loss time, loss metal and the hazards incorrect castings which may have passed inspection approval. Some drop forging designs may produced closed dies with flash parting line order attain ad- ditional quality features. Parts such piston pins, counterweight pins and impeller gear shafts are some- times forged this manner. ro- tating the steel billet the die dur- ing forging reduction, the excess metal extruded into small gate, instead being forced out into the gutter surrounding the die impression. This method operation often times termed centrifugal forging and specified for purposes controlling grain flow and eliminating the crack- ing possibilities steel heat treated extreme hardness. Counterweight pins stainless type A.M.S. 5630 are specified for wear and corrosion re- sistance. This type which per carbon, per cent chrome, per cent molybdenum quires cooling dry lime after forg- ing and slow cooling annealing after soaking 1650 deg. for period hr. Exhaust flanges are forged from stainless types 347, 321, 416 and 414 for heat and corrosion resistance. Some other applications stainless steel forgings are gun mount posts, cartridge starters, rotor bushing, oxy- gen cylinder bosses and magneto shafts. The upset forging machine has many distinct advantages for designs which lend themselves this method production. Forgings pro- duced with deep pierced holes uni- form side wall thickness and practi- free from parting line flash. These features make this method par- ticularly adaptable the production aluminum pistons, cylinder liners for aircraft and torpedo engines, shell bodies, gears, pinions, hubs and flanges. Prior the war only steel forg- IRON AGE, June 1944 ings with fairly symmetrical shapes were produced closed die forgings forging presses. The demand for more forgings than available hammer capacity could produce encouraged further study die design which would make press operation possible operation press forging large steel ingot into gun tube. the more intricate steel designs. However, press forging these ir- regular shapes limited because insufficient space for the necessary blank. Consequently, such parts are produced the hammer because number blows can struck the tooling for the preliminary operations. Instead making number forg- ings from one length the bar drop forgings, cut blank shape for each forging necessary press forging operations. Brass, copper, aluminum and magnesium forgings within limitations size and shape are produced advantage the forging press because the good ex- trusion characteristics these metals. Each operation step completed one squeeze the metal what- ever tooling necessary for the par- ticular design. The development aluminum and magnesium alloys increased strength has been invaluable the aircraft parts designer reducing fabrication costs and improving the strength weight ratio the parts. Landing gear assemblies formerly re- quiring the welding many steel parts have been reduced one aluminum alloy forging. Fur- thermore, this change reduced X-ray rejections from per cent prac- tically nothing, decreased machining costs and considerably improved the appearance the job. Forging Aluminum Alloys There number aluminum al- loys suitable for die forging—their selection being dependent upon the appiication intended. Types 14S, 17S and 25S are commonly used for many forging parts and tensile strengths 65,000 psi can developed for the 14S type after precipitation age hardening. The most readily forge- able the aluminum alloys and for that reason often used for large and intricate parts. The dis- advantage this alloy that will not develop mechanical strength, and therefore its usefulness for many purposes somewhat lim- ited. Aluminum has much higher fric- tion co-efficient than steel, making more difficult flow into die recesses. For this reason and because the narrow forging limits deformation, aluminum alloys require about two times the number hammer blows that would necessary for the same part forged from steel. words, the hammer size about twice that required for steel order approximate the same production. The shrinkage allowance forging dies for aluminum and magnesium alloys figured in. per ft. for large forgings and 1/10 in. for the small parts. exception this rule large propeller forgings in. lengths which contract 3/16 in. the ft. due the fact that there obstruction the design hamper the shrinkage. Die forgings magnesium alloys require larger radii and filets than aluminum and steel. There are sev- eral commercial alloy types this metal which are forgeable within fairly narrow temperature These limits range from about 600 deg. 775 deg. for press opera- tion Dowmetal and from 600 deg. 825 deg. for Dowmetal which adaptable either hammer press forging. Magnesium alloy forgings will pro- duce tensile strength values 46,000 Ib. per sq. in. the as-forged cond 8.5 man are than Whe num loys grea forg abot whe’ part crea gini min and ings com and thes for cher the dens ities all ject flux : 2 ° ° ° plifi sold and roll ano’ sold roll pen: the whi the han We — condition for type which has about 8.5 per cent aluminum, 0.20 per cent manganese and 0.5 per cent They are somewhat more difficult forge than aluminum alloys, especially those designs having thin web sections. Where possible forge alumi- num design with minimum web thickness, magnesium loys require 3/16 in. greater thickness. The number forgings produced from the die before reworking averages about two-thirds the die life, which somewhat less than that obtained when forging aluminum part. tremendously since the be- gininng the war and there doubt that this metal, having weight about per cent alu- minum, will have increased use peacetime production. order withstand the speeds and stresses modern design, forg- ings must provide the maximum re- sistance torsional, tensional and compressional strains well shock and impact. assure attainment these specifications, the forging bars billets are inspected before release for forging production. complete chemical analysis and etch tests the billets are made check the density, segregation and surface qual- ities. aid this inspection, all steel magnaflux quality sub- jected standard routine magna- flux procedure. sample bar length, least equal that required for one forging and representing the top and bottom the first and top and bottom the last ingot poured, and addition two more samples taken from random bars other locations the heat, are selected for Magnaflux examina- tion. slice cut from the end each these samples macro-etched for determination porosity, ingot struc- ture and pipe. The continuous wet method with the application 1000 amp. per in. cross-section stand- ard with Transue Williams. Sam- ples square bars billets are cut pared turning sample out one- half the cross-section centers mid- way between the edge and center the bar. The samples are stamped for identification the center sec- tions and then heat treated high Brinell readily machinable. This heat treatment remove any banded structure and increase the ability the piece retain magne- tism. After machining round test sizes, the samples are ground smooth ready for magnetic testing. permanent record all tests made imbibition paper (unsensi- tized photographic paper) and the prints are filed with complete rec- ord the heat, indexed the par- ticular lot forgings produced. The prints are prepared