The Iron Age 1944-08-03: Vol 154 Iss 5

VAN DEVENTER President and Editorial Director BAUR Vice-President General Manager ° ° ° Editorial and Advertising Offices 100 East 42nd New York N.Y., U.S.A. Johnson, Market Research Mar. Hayes, Production Manager. Baur, Typography and Layout ° ° Regicnal Business Managers New York New York 100 East 42nd St. 100 East 42nd St. ROBERT BLAIR GIBBS 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 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 Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents. ° ° Cable Address, Y." ° Copyright, 1944, by Chilton Company (Ine.) IRON AGE Vol. 154, No. Editorial Men vs. Boards Technical Articles Non-Ferrous Alloy Blanking Dies What Quenching Oil Use August 1944 Welding and Cutting Adapted Line Production Stainless Steel and Magnesium Pickling Guide Furnace Selection Influence Alloying Elements Cr-Ni-Mo Steel Reclamation Electrical Insulating Varnish ° ° ° Features News Front Assembly Line Washington West Coast Personals and Fatigue Cracks Dear Editor This Industrial Week News Industry News and Markets Wage Increase Case Heard WLB Panel Lay Little Steel Formula Case Before Army Uses Only One Out Ten Skills Cutback Controls Decentralized Westinghouse Makes Refunds Machine Tool Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Prices Iron and Steel Scrap News and Prices Comparison Prices Year Finished Iron and Steel Prices Steel and Prices Semi-Finished and Tool Steel Prices Steel Pipe and Tubing Prices Wire Product Prices Pig Iron and Coke Railroad Material and Stainless Steel Prices Ferroalloy Prices Index Advertisers 4 ° ° ° A. | FOR DISCRIMINATING USERS complete line wire, rod and bars 4 IRTH-STERLING—a mill with national reputation for consistently high quality Tool and Alloy Steels— special requirements discriminat- Stainless Steels Meet Special Requirements such as: Closely Controlled Compositions. Physical Requirements. Precise Size and Shape Tolerances. 1913, when FIRTH-STERLING made the first Stainless Steel produced this country, have specialized made-to-order types for the most ex- acting specifications. Literature available, giving complete details. Ask For: Bulletin No. SL-2009 Types 420, 440-A, 440-B, and 440-C. Bulletin No. SL-2010 Types 403, 410, and 416. Bulletin No. SL-2011 Types 302, 303, and 304. Bulletin No. SL-2018 Cold Fin- ished Stainless Steels. STEEL COMPANY ing users Stainless Steels. Since t * 42—THE IRON AGE, August 1944 Offices: McKeesport, Pa. New York Hartford Philadelphia Cleveland Dayton Detroit Chicago Los Angeles 4 ~The ESTABLISHED 1855 ° ° ° August 1944 ° ° ° VAN DEVENTER President and BAUR Vice-President and General Manager ° ° DIX Monager, Reader Service ° ° Editorial Staff Commercial Editor, CAMPBELE Associate Editors WINTERS BARMASEL TRUNDLE ALBIN Editorial Assistants SCHIEN WILLIAMS ROGERS Regional News and Technical LLOYD Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis Bidg. W.. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press MacDONALD Cleveland 1016 Guardian BRAMS 7310 Woodward Ave. OSGOOD MURDOCK Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, RAYMOND KAY Los JOHN McCUNE Birmingham ROY EDMONDS Louis JAMES DOUGLAS Men versus Boards have big job do, that must done quickly and well, are not turn millions workers out jobs after the war, let alone employ our returning soldiers. That job the equipment shift and primarily the machine tool shift which the major part it. Few people realize what big job this is. During the years between 1900 and 1936, the American machine tool industry produced, years, tools totaling $2.7 billions value. During the six years prewar and war preparation and execution ended 1943 this same industry produced products valued $4.4 billion. Some this productive equipment went abroad but the greater part went into American manufacturing plants and there now turning out munitions. large part owned Uncle Sam. Now Uncle Sam not going operate manufacturing after the war and munitions making going very small part our requirements, hope. But present, the government owns approxi- mately 500,000 our machine tools, representing total more than per cent more tools than were use this country under private ownership 1940. So, are have postwar employment adequate prevent disastrous depression, title these tools must changed from govern- ment, which not the manufacturing business, private enterprise, which is. Five hundred thousand government owned machine tools work war industry not begin measure the magnitude the postwar conversion job because private industry has devoted probably per cent more its facilities war purposes. Nor 500,000 machine tools mean merely that number jobs. For every machine tool work, normal times, means the employment least four additional people, servicing, maintenance, supervision, transportation, selling and other related services. The Baruch-Hancock report the President set forth the urgency this problem plain English. effect said: “We can’t release these tools from war work now, but for God’s sake get things ready promptly when the time comes.” Well, what was done about it? Naturally, with involvement billions dollars tax-payers’ money, was Congress pass enabling act. But what can you expect election year? Even the face the appeal Baruch and Hancock “hurry, hurry, hurry.” the President (God bless him this particular instance) put the job into the capable hands Clayton, working through the RFC. And Mr. Clayton, now charge all surplus equipment, mach‘ne tool and otherwise, has surrounded himself with extremely capable staff that knows its business. There are now some twenty-six bills before Congress, most them with political axes grind, specifying how surplus equipment shall sold. And most them involving the setting board for that purpose. With few notable exceptions, boards are something that lay around for people stumble over. capable man, given authority can move ten times faster and surer than any board which has meet, discuss, debate, deny, dissertate, dilate and delay. Yes, Congress should pass the enabling act and specify the terms under which this equipment can shifted. But should put the job the hands live man and not inanimate board. | Destroyer Escort Named for Inland Hero few weeks ago sleek destroyer escort vessel slid into the water the Defoe Shipbuilding Company’s yard Bay City, Michigan. was the USS Gosselin, named honor Ensign Ed- ward Gosselin who was killed during the attack Pearl Harbor. left In- land Steel Company October, 1940 enlist the U.S. Naval Reserve. His was the first gold star placed the In- land service flag. interesting and also fitting that Inland steel was used constructing the USS Gosselin. Since that day Japanese treachery, Inland has supplied hundreds thousands tons steel for cargo and naval vessels many types—ships con- structed the Great Lakes, river yards, and tidewater. Inland will continue produce steel maximum capacity for the war effort un- til Victory ours. look forward then helping build the better peacetime world for which our boys are fighting. INLAND STEEL COMPANY Dearborn St., Chicago Illinois Branch Offices: Cincinnati Detroit City Save fighters’ buy more War Mrs. Edward Gosselin, ties Mach one pow gro dus if gt = News August 1944 The Brassert Company hiring design engineers work plans for 140,000 60,000 ingot ton yearly steel mill for the Corporacion Fomento hile. Since coal poor there and electricity cheap, the plant likely will based electrical energy, with perhaps even electric "blast furnace". That mustard gas may yet employed against American soldiers this war the War Department. soldier being equipped with three capes protection against contact with the gas. Each cape equivalent 190 cigarette wrappers, which explains the disappearance such wrappers over months. Germans are experimenting with jet-propelled flying mines. Such unit two magnetic mines recently crashed South Sweden. occasional crashing crewless bombs Sweden and Switzerland indicates experimental steering apparatus going completely awry, the Germans are dropping units into neutral country check their calculations range and accuracy. ortugal, Berlin has announced that "artificial wolfram" has been devised which quite good the real thing". WLB's statement that without power approve union demands break the ittle Steel formula indicates that the entire problem adjusting the formula will laid before the President. Presidential action taken change the formula any single union would credit for the upward adjustment. American Optical Co. cooperation with the Apprentice Training Service the has formulated program for the war veterans. Employment and service records will examined for ability, education, experience and qualities leadership. Where improvements have been made skills, experience and ties, attempts will made fit these men into more responsible positions. Declaring that the lack long range planning attacking the problem backs appalling, Harvey Brown, president the International Association Machinists, AFL, suggested better coordination between military agencies that when branch cancels contract, another can step into the breach with other work that remains done. Cuts should concentrated those companies and areas where the released power and facilities can most readily adapted other production uses. When backs become most severe, the work week should lowered the prewar 40-hr. level. Impact the war the West Coast has reversed the usual law industrial growth. Far Western industries find themselves with modern, improved, efficient dustrial facilities and trained working force, but without sufficient immediate continue war sized operations. Only hiatus the West Coast postwar pessimism the hope that Geneva's could pass into private, independent western hands sufficient discount produce competitively, and railroads grant low enough rate the West Coast deliver finished and semi-finished steel roughly competitive basis. Shell steel production expected hit 450,000 tons per month Jan. 1945, forging facilities may not able handle this tonnage that early. tonnage may not develop. Present rate has reached about 200,000 tons and fast. Structural, rail and tube round mill products are suffering from for rolling capacity for shell billets and bars. Out approximately 1,400,000 jobs and employees manufacturing industries States west the Rockies present, loss half million expected for per- peacetime operation. However, this area now short 50,000 workers. Bomb damaged mutilated steel landing mats are being treated "on the The reconditioning plant made series portable units can straighten and clean bent steel plank landing mats location. Its rela- light weight and compactness permits flown from one damaged airfield another. Since American pressure has cut into German importations wolfram from Spain and 4 q 4 | g The introduction the aircraft industry inexpensive zinc dies has not only revolutionized aircraft practice but also promises new possibilities in, say, automotive production. These dies make possible greater competition reducing monetary investments dies and permitting rapid model changes. this three-part article, British practice the use non-ferrous alloys for aircraft dies traced from the early use high strength die casting alloys the K.M. alloy. addition, tool and die well template production are fully discussed. This article re- produced courtesy Sheet Metal Industries, London. which the aircraft industry has face when tooling for new type machine the manu- facture and supply the thousands press tools and blanking dies necessary before can put production basis. Another factor, which these times further aggra- vates the position, the small mar- gin time that available between the issue component drawings from the design office and the target date set for the commencement production. The Bristol Aeroplane Co., Ltd., (Aircraft Division) has, over the past six seven years, been experi- menting with various types tools with view arriving one which could speedily manufactured with the minimum number skilled tool- makers and suitable for operation unskilled labor. The introduction the rubber die technique helped relieve the strain the tool room effecting change the design considerable num- ber bending and forming tools (previously produced along conventional lines) simple type form blocks manufactured from zinc alloy, one the many hard wood synthetic compositions. The com- pany’s efforts were subsequently de- voted designing simplified blank- ing die which could standardized meet the majority the sizes which would required. The ortho- 46—THE IRON AGE, August 1944 1944, 56. dox type blanking die, manufac- tured entirely from cast iron and steel, obviously costly manhours and material, particularly with re- gard the comparatively small num- ber pressings which are required for any one type aircraft. tool this type, such the one illustrated Fig. requires very highly skilled toolmakers for its manufacture; entails the use very expensive machinery, such For additional data the use zinc alloy dies the aircraft industry, see the following articles AGE: “Job-Lot Aircraft Oct. 19, 1939, 50; Oct. 26, 43. “Zinc Alloy Dies for Drop Hammer Work,” Feb. 1940, 29. “Drawing Dies for Airframe Stamp- ings,’ May 28, 1942, 37. Forming Contoured Sheet Metal Aircraft Parts,” June 1942, 49. “Forming Convex Flanges and Jog- gles,” June 11, 1942, 49. “Coring Kirksite April 1943, 84. “Kirksite Die Technique,” June 10, 1943, 60. “Steel, Plastics and Zinc Used Com- bination Die Set,” June 17, 1943, 68. Chuck Jaws,” Aug. 1943, 54. “Casting Die Wedges for Light Metal Flanging,” Oct. 28, 1943, 70. “Mass Production Kirksite Blanking Dies,” Jan. 20, 1944, 70. “Production Short Cuts,’ March 16, 1944, 73. “Kirksite Molds for 20, 1944, 71. “Cast Kirksite Blanking Dies,” May punch shapers, and, some cases, Keller profiling and die sinking ma- chines well the usual tool room equipment like lathes, millers and band sawing machines, and extensive heat treatment equipment. More over, special non-shrinking alloy steel, difficult obtain under war- time conditions, used the facture these dies. Despite the use this material not infrequent for die shrink distort the hardening process, necessitating the very lengthy operation stoning out. Furthermore, the case very large blanking dies, necessary build the punch and die seg- ments reduce the distortion which takes place when hardening. This method manufacture demands high percentage skilled man hours. The Bristol Aeroplane Co.’s air- craft division adopted the policy that, unless the required production any particular part was really high, the conventional type press tool, illus- trated Fig. would not paying proposition. simpler type veloped. The type decided upon was intro- duced some two years ago. (See Fig. This blanking die consisted bolster made cast iron with die and mounted with mild steel stripper plate. The punch was also constructed from die steel and made fit the aperture the stripped plate for setting purposes, simple stop pin being provided for the feeding the stock. tion the blank was ejected through the bottom the bolster. range ten sizes varying from in. in. square was designed and these were manufactured fairly large quantities consisting the bolster, die and stripper plate, but with the die steel left blank and its soft state. These standard blank- by cases, ma- room ensive More- alloy manu- use the the out. very seg- which This ids hours. that, any the illus- intro- (See sisted with mild was and the poses, for rough ing die sets were made batches trainee labor. addition the standard blanking sets, range sandwich type drilling jigs was de- signed and order speed manu- facture these tools still further, the jig and tool design office prepared drawing sheets, shown Fig. printed with the outline these tools. Therefore, whenever the design blanking die drill jig was required, the jig and tool draftsman had only fill the developed shape the part and centers any holes which might required, together with the addition the working dimensions onto the appropriate size drawing sheet, the tool then being ready for ordering. The tool room, receipt the tool drawing, obtained from the stores the correct blanking die set which was then passed the toolmaker for completion. This type die proved very satisfactory use and showed considerable saving the time skilled toolmakers. being extensively used today, par- ticularly where heavy gage metal blanks are required. Blanking The majority airplane detail parts are manufactured from light alloy sheet and the company felt that even simpler type blanking die could devised. was connection with research along these lines that the use zine alloy, which was al- ready known meeting with con- siderable several American factories, was considered. The alloy used the American factories known Kirksite but diffi- cult obtain under war conditions England. direct result the pioneer work the company, how- ever, new alloy was developed conjunction with National Alloys Ltd.* and the Ministry Aircraft Production. This firm produced five Smelting Corp., Ltd. sample alloys plate form which were submitted Bristol for re- search purposes. Blanking dies were made each the five alloys and given considerable runs under production conditions. The results these tests far ex- ceeded the com- expecta- tions, the alloy designated “K.M.” proving most satisfactory. * The blanks produced from these dies were entirely free from burr and, even after some 2000 had been run off, their quality had not deteriorated. would not understatement that the quality these blanks equalled and, some cases, surpassed those produced from expensive steel dies. The K.M. blanking dies showed such considerable saving the man hours required for their manufacture compared with any ° ° ° 2—For limited production runs, the blanking dies shown here were developed about two years ago. The die consists bolster made cast iron with steel die and mounted with steel stripper “ame Conven- tional type blanking die, made entirely iron and steel, re- quires skilled toolmakers for its manufacture. this previous forthwith adopted their use wherever possible. detailed description the design and method manufacture developed will given later this article. type company The use zinc alloy the mak- ing dies for forming sheet metal components was develop- the early stages this work when straight alone was THE IRON AGE, August — igned lank- Scrap section through s.s. stop Bolster the high strength zinc die casting alloys for its die material, tured under the name Zamak the United States and Mazak and Durak England. These alloys, containing 3.9 4.3 per cent aluminum, 0.03 0.06 per cent magnesium, and vary- ing quantities copper, are manu- factured from 99.99+ per cent pure the United States, large mea- sure credit for the adaptation Position Parallel Kirk Sons, Inc., Los Angeles. This Scrap section through s.s stop Drive fit Unbrako screws dowels Parallel Allow 0003 clearance round and die used. that time this material was employed for cast drop hammer dies, usually conjunction with an- timonial lead punch which was cast directly into the zinc die, but ex- perience showed that the unalloyed state, zinc was not strong enough withstand the severe stresses im- posed. Aircraft manufacturers, there- fore, searched for better materials, and for time alloy with per cent copper was used fairly extensively. This alloy, while having better mechanical proper- ties than unalloyed zinc, was still sufficiently strong for the purposes required and, addition, was found suffer from iron “pick-up” when melted cast iron pots. Copper, alloying addition the alone, does not cause any appreciable grain refinement, consequently large cast- ings slowly cooled tend brittle. The properties this alloy, compared with those unalloyed zinc, are shown Table was not unnatural, therefore, that the aircraft industry turned 48—THE IRON AGE, August 1944 ABOVE 3—Standard blanking die draw- ings. Whenever the de- sign blanking die drill job was re- quired, the draftsman had only fill the developed shape the part and centers any holes which might required. Working dimensions added. RIGHT per additions per cent the shear strength compression and the Brinell hard- ness high purity zinc containing 4.1 per cent aluminum and 0.04 per cent magnesium. Die-Vital Back off company selected, from the range Zamak alloys, the alloy Zamak most nearly satisfying the require- ments the aircraft industry, and for time manufactured under the name Kirksite under license from the New Jersey Zinc Co.* The composition this alloy, which was Alloy Dies for Drop Hammer Work,” Broughton, Tue Iron Feb. 1940. also manufactured England under the name Mazak was follows: ream Aluminum ......... 3.9 Punch-Vital hd.and Magnesium ........ 0.02 0.05 Remainder Subsequently the Kirk Company modified this composition obtain greater strength and hardness and introduced new alloy known Kirk- Shear stress, tons per final cross sectional area Brinell hardness number Copper, per cent | } | | } | nufac- the Durak aining ).03 pure mea- ion This ige quire- and under icense The was immer under 1.3 2.9 ).05 der and Kirk- site which found immediate favor and has been adopted large and extent the United States for the construction dies for stretching and blanking operations, well for drop hammer work the fabrication light alloy panels and sections for aircraft. The graph Fig. shows the effect upon the shear strength compression and the Brinell hardness additions purity zine alloy containing 4.1 per cent aluminum and 0.04 per cent mag- nesium. England some similar develop- ments have occurred. Owing the heavy call upon the die casting indus- try for the manufacture munitions, was decided early the war concentrate the production one alloy, namely Mazak copper- free alloy. Neither Mazak nor Mazak the zine alloys containing copper, have been produced com- mercial scale during the war. There was, however, the early days the war, limited production Durak which one the Mazak series alloys and has the same aluminum and magnesium contents Mazak but contains per cent copper and trace manganese. the early stages the development zinc alloys for forming dies, Durak was probably the most frequently used. Subsequently, however, production Durak had suspended owing K.M. alloy cast. One per cent nital etch, 100 diameters. TABLE Properties Zinc Copper Alloy* Zinc, per cent Zine (Cast) Copper (Cast) Compressive strength 18,200 Ib. per sq. in. 28,600 Ib. per sq. in. and Its Alloys,” 1931, Bureau Standards. shortage supplies, and accord- ingly the aircraft industry has until recent months been forced rely secondary zinc alloy for its die material. keep pace with increased uses developed the aircraft industry, new alloy now available, made from virgin materials. This called K.M. alloy, and similar composition Mazak but the composition has been modified give additional strength and hardness. The basic zine 99.99+ grade, and the im- purities are controlled during manu- facture (as with the Mazak alloys) below the following maxima:— Per Cent 0.003 0.075 The necessity keeping the low melting point metals, particular A, 6—Rolled lead, cadmium, and tin, down ex- tremely small proportions zine al- loys containing aluminum has been amply described the literature*. sufficient, therefore, note that *Brauer and Pierce, Transactions M.E., 1922, 22, the presence little one part 10,000 any these elements will cause intercrystalline corrosion develop upon aging, particularly warm, humid atmospheres. This in- tercrystalline attack accompanied swelling, distortion, cracking, and loss strength and was responsible for the unfavorable reputation gained the early die casting alloys manufactured before the commercial production 99.99+ per cent pure addition its role pro- moting corrosion, tin, small proportion 0.007 per (CONTINUED PAGE 132) BELOW ructure K.M. alloy, etched per cent nital, 980 diameters. = 4 > a y, * q q 7 THE IRON AGE, August author’s first experience with prominent metallurgist occurred about years ago, time incidentally when had job his hands trying master the intracacies the oil business. The metallurgist spoke easily and rapidly about subcritical tempera- tures, the isothermal transformtion austenitized carbon steels, curves, TTT curves, pearlite, sorbite, troot- site and finally displayed all these things magnified photographs, hun- dreds them, and like finger prints two were alike. The writer felt like Anthony Leeuwenhock, the famous Dutch janitor, who was the first build and peer through microscope. Here was another strange world. The writer’s original purpose had been try and sell little mineral 50—THE IRON AGE, August 1944 What Quenching Oil Use oil accomplish all these things, simple mineral oil such might used lubricate the bearings sewing machine, lawn-mower, but was overwhelmed this new world strange terms and microscopic interpretations that was ashamed mention such foolish idea. When came time ven- tured ask obliging friend what kind oil used secure all these intriguing results, and there again was confronted with first class mystery. use three types quench- ing oil” replied friend, “each one has its own peculiar characteristics, they are specially made meet requirements and they contain in- gredients which enable ac- complish what you have There was the answer the whole thing. But this was not first brush with medicine men, nor last, and while felt very discouraged about show- FORBES Tide Water Oil Co., New York “FOR operations there disputing the fact that mineral oils are much more re- sistant decomposition and change. important con- sideration when dealing with that contains many other variables, many them classified ing complete ignorance from the start this interview ig- nominious departure made mind add the study metallurgy list hobbies. But the meantime had those mysterious quenching mediums analyzed petroleum chemist. Now let skip the ensuing years and the many hours pleasure have had reading many books metal- lurgy, chemistry, petroleum and few other subjects. Let also skip the petroleum terms that could now counter with were meet metallurgical friend again. For his isothermal transformation curves, could stack viscosity index curves; for his martensite could add- lib with neutralization member, interfacial tension and solvent refining. our contest looked like draw could attempt stump him with casual remark about the com- plex metallic additives now certain types petroleum products the straight chain type. here that re- and con- hem the ig- urgy the rious years have few the now his ndex add- nber, like him com- use lucts years later, would least have better chance engaging dis- cussion that would not com- pletely one sided. could add own quota the babble confusion. But here the strange conclusion have arrived at, after considerable observation quenching with oils many types. And dispel early some popular misconceptions about quench- ing oils, let say that m y friend would have been much better off had just purchased sawing machine oil. might have saved him- self many head- aches that did not tell about, his photomicrographs would probably have been more uniform, and might have been better able control his operations. know this now, because the first his mysterious quenching mediums was straight refined whale oil, the second was mixture min- eral oil and fish oil, and the third was mixture mineral oil made soluble water with the aid soap com- pound. The line-up was means un- sound, but the manipulation these three mediums must have required the skill top notch juggler. fact, the Indian rope trick was being out before unsuspecting eyes, and with gold brick hand that was all the while turning lead. Suppose now agree set aside all technical terms and examine the subject quenching. the first place not know what actually steel become hard when heated above certain “critical” tem- perature, then plunged into something cold. However, have micro- scopes, cameras, hardness testing ma- chines, record the before and after effects. With these aids can find out with reasonable accuracy just what has occurred after the quench- ing operation. the steel comes out hard and brittle like piece glass the quench has been too rapid; soft and similar its original form, the quench has been too slow. be- tween these phases lies the most de- sirable result for particular quench- ing operation. This where all the work and study comes with its endless diagnosing from trial and error work with specimens. This the headache the metallurgist, and the reason for his never ending search for quenching medium that obligingly about its business and produce the desired result with- out lot study and fussing. For similar reasons the people this country purchase three hundred mil- lion dollars worth vitamin tablets every year; the majority chance that two three day will benefit them. Maybe does. not know. However, know that vitamin tablets won’t the trick quench- ing oils. Here are confronted with the request THE IRON AGE, the author herein sets forth provocative language his preference for mineral oils for all types quenching. Mr. Forbes the author two recent text books published John Wiley Sons, Inc.: “Lubrication Industrial and Marine and “Lubricants and Oils for Machine Tools." the problem cooling piece steel many seconds secure desired result. Water too fast for most operations, assuming that oil decided upon cooling medium, the choice ranges over wide field. Animal and fish oils have slight edge mineral oils because their cooling rate slightly less rapid. But this advantage soon nullified actual practice because they de- compose and thicken more readily than mineral oils when subjected heat with the result that the cooling rate changes very noticeably when compared with the same operation using straight mineral oil. Hence this lack stability throws monkey wrench into any continuous quench- ing operation. This disadvantage quite apart from any objectionable odors that develop, and the higher cost animal and fish oils. Plant oils may ruled out entirely because they oxidize much too easily and have drying properties. mineral oils are blended with fish animal oils the tendency towards decomposition course lessened pro rata, but the over- all advantage becomes negligible. Hence maximum resistance de- composition important factor, and mineral oils exhibit much greater resistance decomposition than any other type. The next problem encountered that vapor bubbles forming and sticking the surface the hot steel. this connection animal and fish oils have lower surface tensions, hence they are believed flow creep over the hot steel better than mineral oils and result dislodge these vapor bubbles more readily and make the quench more uniform. This theory has led considerable re- search along the lines endowing mineral oils with this same virtue. not hard accomplish, and many materials have been added that will this, but the practical results have not substantiated the theory any noticeable extent. However, there another effective and simple method that will dislodge vapor bubbles and that circulate the oil. This simple procedure will dislodge vapor bubbles tively and the oil need only flow gently one direction quickly dis- tort and liberate all the balky vapor bubbles that form the surface advantage circulating the oil the benefit derived from maintaining the oil reason- ably uniform temperature. The next question the type mineral oil best adapted quench- ing. this connection the most popu- lar type known the trade name “28 Paraffin.” This light oil distilled from paraffin base crudes such are found the Pennsylvania and Mid-Continent fields. The vis- cosity measured the Saybolt in- strument approximately 100 sec. 100 deg. The trade name “28 Paraffin” merely derived from the fact that this type oil has gravity reading above, when tested with hydrometer using the gravity scale the American Petroleuin In- stitute. When the quenching opera- tion such that considerable mist raised the quenching operation, Saybolt viscosity 200 sec. 100 deg. However, best results are generally secured with the lighter oil. The temperature the oil important factor all quenching operations, particularly the main- tenance uniform temperature. the temperature the oil deg. one time and 180 deg. another time there will some vari- ance the results. Hence should obvious that means must pro- vided circulate the oil and tain the temperature within reason- able limits. The next question the best oil temperature for most quenching pur- poses. From practical experience and many expressions opinion this tem- perature appears anywhere be- tween deg. and 120 deg. Mineral oils, any other type eil for that matter, will oxidize and break down with service. The oxida- tion process causes products form and the extent this action may determined the test for neutralization which (CONTINUED PAGE 136) THE IRON AGE, August | | 7 | q extensive use flame cut- ting and arc welding quantity production operations has fo- cused the attention industrial en- gineers upon means for integrating these processes into production-line techniques. The comparative ease with which cutting and welding can or- ganized fit with continuous production scheme becoming better known, now that war production has settled into smooth, permanent stride, with much this work be- ing done welded fabrication. The difference between produc- tion-line method manufacture and the more common system break- down operations chiefly one degree. addition this quantita- Welding and Cutting tive difference, however, there qualitative difference. One the most common methods manufacturing quantities assembly requiring number different operations per- formed sequence the work lots batches. This usually entails repetitive handling, larger inventory unfinished work and space for tem- throughout the plant. Both costs and manhours per finished piece are usu- ally higher this method than when overall procedure approaching true production line can set up. The essential, qualitative difference between the two methods that with the line the work unit one piece rather than batch pieces beam member 52—THE IRON AGE, August 1944 —Transfor- mation stand- ard pat-- ented Globe hatch shifting beams. Beam oxyacetylene flame split longitudinally along the web; ends are flame cut hand, employing templates; V-notches are flame cut and beveled welding edges. Parts are then jigged after forming bottom member; struts, plates, angles, etc., welded in, and hatch shifting beam complete. and this one piece kept active production from start finish. the Globe Co., Chicago, where hatch shifting beams are being fabricated welding, this method has effected reductions handling, the tonnage steel needed keep all work sta- tions busy, the time lapse between start and finish each beam and the total working space devoted the fabrication this item. the last analysis has resulted extreme- low cost per ton steel fabricated. The hatch shifting beams designed the Globe Co. and its associates are new type. They are both lighter and stronger than the straight run structural mill ously used for this purpose. Since their introduction more than year ago they have become standard equipment all Liberty and Victory ships. Because the production meth- ods employed, output these beams has been satisfactory that Globe employees have been awarded the Maritime “M”. Quick Conversion Made Prior setting for the fabri- cation hatch shifting beams and other war work Globe had manufac- tured machinery for the meat packing industry. Yet the days following receipt the first order from the Maritime Commission, the company began making deliveries. this short period the shops were completely re- arranged accommodate the installa- tion the essential new equipment and work schedules were laid out which proved effective initially and which, with but few modifications, are still practice. Progressive integra- tion techniques along the line have enabled the company make price reductions the Maritime Commis- sion since the job began. Each Liberty ship requires hatch shifting beams, weighing total 53,935 which about per cent tons less than required the original design. The Victory ship re- quires beams totaling 80,220 Ib. The new beams (patent pending) were designed that changes were re- quired the ship’s hatch structure accemmodate them. Beams for each individual hatch are interchangeable, being made length tolerance beam Adapted Line Production 0.25 0.000 in. This accuracy was easily possible beam fabrication, but worth while only after mu- tual cooperation the part the Maritime Commission, Globe and the shipbuilders enabled the latter ex- ercise fine control over the fabrication the hatch coaming structure into which accurately made beams could readily fitted. The diagrams Fig. show three stages the conversion standard in. I-beams the fabricated type beam. Fig. detailed material flow diagram, with each work station identified number which will referred the following step-by- step description operations the production line. ° ° FORREST WALDO Applied Engineering Department Air Reduction Sales Co. the Globe Co., Chicago, particularly successful production- line technique has been developed for the welded fabrication hatch shifting beams for Liberty and Victory ships. Continuous pro- duction smoothly organized that monorail conveyor used carry the beams from one work station the next, and much possible the performance each operation planned minimize eliminate the possibility workers getting ahead schedule the building surplus stocks any stage fabrica- tion. The standard I-beams are received rail cars containing 106 beams different weights, sufficient for fab- ricating two complete sets members. number these are delivered di- rectly rail storage, station within the plant for immediate feed- ing into the production line. Surplus I-beams are stored the steel ware- house adjacent the plant. When needed, these are placed crane trucks and wheeled into the plant 2—This production layout indicates the flow material, beginning the raw material storage and moving through the produc- tion line the carloading station where the finished product forwarded its destination. Radiagraph beam splitting bay Eu Com ~ THE IRON AGE, August ° ° ° ated nage veen the last ates both ight revi- tory the bri Beam Saw king ving hort nent out and are rice Shear mis- 1G. 3—The beam splitting bay. Roller conveyors and over- head air hoists feed the beams jigging tables for tudinal splitting. LEFT 4—Beams are split single Radiagraph with two torches mounted fixed track between two jigs holding beams. Operator with hand torch follows closely behind machine, cutting tapered ends and notches bottom members, using guide fixtures. ABOVE F's. 5—After the Radiagraph completes the longitudinal cut, operators with hand torches and guide fixtures cut the ends shape for fitting. LEFT IG. 6—The V-notches cut the bottom members while the beam splitting table are hand torch beveled prepara- tory bending and welding. removable arm rest em- ployed for steadying the operator's guiding hand. This job done transit. ; nal the station More than two carloads beams are fed into the line each day. Start Production The first step conversion the the Globe beam takes place when the beam shifted from the stock pile skid rack and then onto roller conveyor leading friction saw. While the conveyor the beam scribed for oxyacetylene flame cut- ting, using templates. then rolls the Ryerson friction saw, station where one flange sawed through and the web sawed part way through, reducing the top half the beam the ft. 11% in. length re- quired for the upper member seen Fig. This operation, which takes only min., followed the trim- ming the lower flange with oxy- acetylene hand torch, used conjunc- tion with guide fixture, provide overall length ft. in. Be- fore leaving this station the beam marked with its order number and type, and its entry into the production line recorded. Here the production line divides 7—A view the weld- ing area. There are ten bays this area, each having jig, cradle, table, overhead conveyor and air hoist. Hand cars deliver parts for two complete hatch shifting beams each bay. ° ° ° into two main streams. The roller con- veyor leading from the saw deposits the beam onto one two conveyor beds, shown Fig. These beds roll transversely wheels engaging tracks fixed the floor, permitting the beam located beneath one the other four monorails which will carry cutting table. While the conveyor bed one end the top half cut shape with hand torch using steel guiding template fixture. Burrs remaining from the sawing operation are removed this point with pneumatic grinders. The beam then lifted with air hoist ° ° welding jig. Setup men load the jig and lock the members. Welders tack and butt weld all one side hatch beam. Beam then shifted cradle. slung from the overhead monorail and moved along the Airco Radiagraph beam-splitting fixture table, station There are two these fixture tables, each served two monorails and equipped split two beams simulta- neously. Four beams are therefore handled once two cutting crews. Splitting the |-Beams shown Fig. each cutting table consists Radiagraph track fixed the center, with positioning stops and clamps both sides for quick positioning the beams. The Radiagraph carries two torches, tilted leading angle the direction travel. With hand torch, starting holes are first pierced the beam webs, in. from the end. Machine cutting split the beams along their centerlines begins these holes and ends in. from the opposite end, leav- ing short uncut ties provide rigidity during subsequent hand cutting oper- ations. These hand cuts are made soon the machine has passed the point where each cut made. First, one end, the web the top THE IRON AGE, August over- y * ig £ member trimmed sharp angle. Then, farther along, two narrow are cut the web the lower mem- ber, allow for subsequent bending. Then the in. uncut ties are severed and the opposite end the top web trimmed the proper angle, shown Fig. Cutting these RIGHT Upon completion all welding operations and the are transferred the welding area center aisle where two overhead mono- rail lines transfer them station. angles and done with template fixtures guide the hand making smooth, accurate cuts. The two halves the beam are now placed scarfers’ trucks which serve the dual purpose providing, ef- fect, worktables for the scarfing op- eration and conveyance the bull- dozer. The using hand torch and demountable steadyrests shown Fig. double-bevels the edges the two and the portions the IRON AGE, August 1944 web edges which will later fitted into welded joints. Cleaners with chip- ping hammers then remove burrs and slag. Straightening Split Beams Air hoists quickly swing the mem- bers from the truck and into position LEFT cradle, the backs the welds the web joints are gouged out with hand. torch and gouging tip. After slag removed clean groove ex- posed for complet- ing the welding. ° ° ° for straightening the bulldozer, station This operation necessary due the slight distortion caused the release rolling strains the I-beam after beam splitting. The bot- tom members, after being straight- ened, are transferred second bulldozer, station which serves beam bender and forms the bottom member its truss shape. Meantime, plate and angles for the struts and center plates the shift- ing beam have been cut shape the Pel shear station and been brought the bulldozer straightening. this juncture, thege parts and the beam members are load. truck, that each truck carries all necessary pieces for two complete hatch shifting beams. truck then moved one the welding bays station Welding Assembly Beam The welding area, illustrated ing bays, five each side center aisle. each bay are welding jig station 6a, cradle and hor zontal table 6c. These are employed sequence and usually all three are stages completion. Welding erators are located overhead platform which also supports verse monorail conveyors with matic hoists for shifting the beams from one position the next. Each welding bay has its own conveyor well its own crew consisting two setup men and four welders. The parts carrying truck brought alongside one the bays, where the setup men use the air hoist load their jig with complete set for one beam and clamp them rigidly position. Welders then tack and butt weld one side the beam and fillet weld two reinforcing end plates. This activity shown the jig Fig. means the air hoists, the men now shift the beam the first position the cradle, which JI © | sis : | truck two This the ted center jig are gen- steel trans- beams Each two rought ere the load parts rigidly and and plates. jig the set- the ich sists several deg. V-shaped sup- ports, holding the beam deg. -angle with the unwelded side facing up. Here the in. top bar fillet welded the top flange. Also the backup the web joints gouged free slag and prepared for welding means oxyacetylene gouging torch, Fig. The beam then given quarter turn the cradle and the welders complete the fillet welding the top bar. The setup men then shift the beam the horizontal table (6c), exposing the incompleted side for welding. After this welding completed, in- spection made all welds, the beam branded and the setup men place T-shaped jigs the center aisle floor, exposing the narrow space be- tween the reinforcing plates both ends, for fill-in welding. From the jigs the beams are picked overhead conveyor, Fig. 10, and carried down the center aisle and out the welding area. While suspended the conveyor the beams receive the final fabrication operations station These consist the cutting 4-in. dia. lifting holes with hand torch and center point, and the grinding edges and corners. Weld spatter and slag removed with chipping ham- mers. The beam straightened the bulldozer sta- tion and inspected for alinement and surface cleanliness preparatory painting. Located the assembly line are Magnaflux and X-ray equipment which are used different intervals check the quality and penetration This also gives each welder the 12—Beam socket bars are eled and slotted this eight-torch Airco Oxygraph, equipped with jig- ged work table and magnetic cam tracer table. Bevels are cut rear set jigs shown. jigs front hold bars for slot cutting. ° ° opportunity inspect his own work with his foreman, thus assuring him- self that doing proper and efficient job welding. Still the conveyor, the beam pushed into the first location the paint spray booth, station where both sides are simultaneously sprayed with one coat red prime paint. then pushed the second location where receives spray gray fin- ish paint. From this point the beam rolls conveyor through infra- red drying chamber, station 10, where drying accomplished approxi- mately min. the beam leaves this chamber stenciled type and destination and moved into position for loading railroad cars. ° ° ° ship beam socket. Each beam requires two. Cuts made are, sequence: cut-off, beveling, U-slotting, and notching 90-deg. subdepartment the Globe Co.’s beam fabrication department the beam sockets are made, two, for each beam. These are attached the inside face the ship’s hatch, coaming port and starboard the and serve support, position and lock the beam place. The Liberty ship beam socket design shown Fig. 11. The Victory ship sockets are larger and somewhat ferent design. The sockets are made from hot rolled steel bars in. thick in. wide, formed the mill with radius all four corners, and having tensile strength 60,000 75,000 lb. per sq. in. Bar stock stored station and once each day sufficient bars for one day’s production are trucked into the Radiagraph cut-off unit station This unit handles bars groups three, with two-torch Radiagraph for producing six cut lengths one operation. overhead crane hoists the three bars the cutoff table, where manual winch positions them against stop for the first cut. The cutting machine, running right angles the bars, carries two torches in. apart and set make its and in. from the end the bar. The cutting six blanks takes about min., whereupon the winch again used bring the re- mainder the bars against the stop. This operation goes continu- ously, using the high speed Airco cutting tips maintain the pace production. The blanks are then handled eight cutting machine, station Two THE IRON AGE. August 1944—57 Mig 90° | 0 = ‘ RIGHT sockets, locking pawls, bolts and beams are loaded into gondola cars for shipment. The beams are securely braced and retouched when necessary with the hand paint spray gun. ° BELOW 13—Pawl-notching the beam sockets done this swinging jig with Radiagraph. The socket locked the swinging jig and the first side the notch cut. The jig then swung deg. and the second notch cut made. cutting operations are performed here, and the worktable fitted with permanent jigs, eight for each opera- tion. The rear set jigs, shown Fig. 12, holds the bars position for beveling, while the front set positions them for