The Iron Age 1944-08-10: Vol 154 Iss 6

President and Editorial Director BAUR Vice-President General Manager ° ° 100 East 42nd New York 17, N.Y., Johnson, Market Research Mgr. Hayes, Production Manager. | Editorial and Advertising Offices Baur, Typography and Loyout Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. 1016 Guardian Bidg. 428 Park Bidg. Philadelphia Chicago Chilton Bidg. 1134 Otis PEIRCE LEWIS WARREN Detroit Hartford Conn. 7310 Woodward Ave. Box RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY Executive Offices Chestnut and Sts. Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH Vice-President GEORGE EVERIT TERHUNE Vice-President VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR Secretary JULIAN CHASE THOMAS KANE HARRY DUFFY CHARLES HEALE Member, Audit Bureau Circulations Member, Associated Business Papers indexed the Industrial Arts lished every Thursday. Subscription North America, South America and Possessions, Foreign, $15 year. Single Copy, cents. J Copyright, 1944, by Chilten Company Vol. 154, No. IRON AGE Editorial Arithmetic and Politics Technical Articles Gun Barrels Machined From Reduced Forgings Packaging Process Protects Precision Parts Selective Copper Brazing Salt Bath Furnaces Use Alloy Steels Plating Practices the Non-ferrous Alloys Blanking Dies Straight-Line Processing Armor Plate Plastic Impregnation Magnesium Castings Low Tin Babbitted Bearings Large Drum Salvaged Metallizing New Equipment Features News Front Assembly Line Washington West Coast Personals and Obituaries Fatigue Cracks Dear Editor This Industrial News Industry News and Markets Coops Expand Activity. Farm Implement Quota Increased for Postwar Steel Export Civilian Production Seen Far Away International Harvester Co. Contract 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 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 August 10, 1944 101 102 103 106 106 134 136 137 138 140 143 145 146 147 148 149 150 215 ° ° | ° © e | Are you getting this important help? Ryerson has always exercised close control over alloy steel quality and for several years has fur- nished the chemical analysis and heat treatment response data with each alloy shipment. Now, this service has been extended under the Certi- fied Steel Plan give new additional informa- tion much more helpful than before. new type Report, containing both hard- enability and analysis data, now being sent with each Ryerson alloy shipment. addition the chemical analysis, every alloy heat stocked Ryerson subjected four separate end- quench tests our own laboratory. The re- sults these tests, when interpreted through tables known physical relationships, reveal the obtainable tensile strength, yield point, elonga- tion and reduction area for and inch rounds quenched and drawn 1000°, 1100° and 1200° Reports include all this test and heat treatment information, plus work- ing temperatures. Thus, you know the complete chemical analysis, what temperatures use; and how the steel will respond heat treatment. Ryerson continues positively identify all alloys. They are color marked according type. Large bars are individually stamped, and smaller bars are bundled and tagged with heat symbol. This identification entered every Report Sheet; cross-reference verification between Report and steel unmistakable. Whether you order single bar many tons, you can sure Ryerson will furnish Reports covering every alloy shipped. Both steel and Reports are delivered together local ship- ments. When shipment made other than Ryerson motor service, the Reports are sent first class mail and addressed the heat treat- ing department. believe the uniform high quality Ryerson alloys—the careful testing—accurate identifica- tion—the new, complete guide data—metallur- gical counsel—and quick shipment—make Ryer- son your number one source for alloy steels from stock. urge you use this unique service. Joseph Ryerson Son, Inc., Chicago, Mil- waukee, Detroit, St. Louis, Cincinnati, Cleve- land, Pittsburgh, Philadelphia, Buffalo, New York, Boston. 42—THE IRON AGE, August 10, 1944 ESTABLISHED 1855 August 10, 1944 ° ° VAN DEVENTER and Editorial Director BAUR Vice-President and General Manager ° fe) ° DIX Manager, Reader Service Editorial Staff Technical Editor........ OLIVER Commercial Editor, CAMPBELL Associate Editors WINTERS BARMASEL TRUNDLE ALBIN Editorial Assistants SCHIEN WILLIAMS ROGERS Regional News and Technical Editors LLOYD Pittsburgh 428 Park POST Chicago 1134 Otis Bldg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bidg. MacDONALD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. JAMES DOUGLAS Seattle Arithmetic and Politics for the fourth term expressed his willingness to,serve but his per- sonal preference was for retirement. believe that with his exceptional knowledge both arithmetic and history, this preference was sincere and that took the candidacy only because his own belief that other Democrat could fill his shoes. Mr. Roosevelt must know that engaging hazardous tilt with both arithmetic and history. Both are “agin” him. And say this with- out reference the precedent involved fourth term. Mr. Roosevelt re-elected and inaugurated 1945, will then years age the calendar. Only two other presidents who were old this inauguration have lived out their terms office, namely Andrew Jackson and James Buchanan. The former was the beginning his second term and the latter was the start his single term. Two others, Harrison and Zachary Taylor, who were the remaining presidents inaugurated comparable age, died within year taking office. With the growth our country and the growing responsibilities the presidency, the age inauguration has decreased. Woodrow Wilson was only the beginning his first term and this age was the oldest president elected office since James Buchanan 1857. The average age all our presidents their inaugurations was and the average age death was 65. Presidents age more quickly than other men due their heavier burdens. Based upon historical vital statistics those holding this highest office since and including Abra- ham Lincoln, president inaugurated the age will have one chance three living out his four-year term. Mr. Roosevelt, with his intimate knowledge history also knows what the first World War did its war president, Woodrow Wilson, even though wisely left the job Commander-in-Chief “Black Jack” Pershing. And also knows that General Pershing, like most Com- mander-in-Chiefs, was retired from active duty the age 64. Mr. Roosevelt not only knows but has made history. made connection with the Supreme Court the United States and its “nine old men” termed them. course knew also that judicial post will stand more age than administrative one, but his belief younger men supplanted the older judges with seven youngsters whose age averaged mere including the 65-year-old James Byrnes. Youth must served. The cold statistics three-to-one chance vice-president becom- ing president case Democratic victory gives one pause for thought. The Kellys’, the Hagues’ and the O’Connells’, knowing their arithmetic undoubtedly took the three-to-one odds into consideration dictating the nomination for vice-president. They wanted man experi- enced mechanization, not idealistic and honest guy such Wallace who does not and has not bent the knee machine wanting someone who was conversant with machinery, they picked Senator Truman, aged 60, who was astonished his nomination, reported, that immediately had nervous breakdown. Well, Candidate Truman knows his machines. should because was one the assistant oilers the famous Prendegast machine which was notorious political and criminal political combination steam roller and bulldozer. pays your money and you takes your choice.” But horse racing fans with common sense not put their money the nose horse that has three-to-one odds against him his chances crossing the finish line. | ° pe. { | ler ol. ort ip- | Ten minutes after sample steel delivered the Inland laboratory its chemical content clearly nently recorded spectrographic film. This film greatly enlarged projection, and studied the spectroscopist. There not chance for any element pass undetected. The apparatus which these checks are made known spectrograph. small specially prepared sample steel Bars Plates Floor Plates Piling Rails Projections the spectrum steel sam- placed the apparatus, where quickly vaporized electric arc, and the trum recorded photographic film. Inland uses the spectrographic tory for frequent and rapid tests while heats are being made. But this only one the many methods used Inland control the quality that uniform from order order—steel that easily fabricated with minimum T¢ ~ « astage. Track Accessories Reinforcing Bars INLAND STEEL COMPANY Dearborn St., Chicago Ill. Bronch Offices: Detroit Kansas City The Case Against “Tramp” Elements New York St. Paul St. Louis q 4 us ls . Pe if iq | News August 1944 The Cooperative Grange League Federation Exchange, Inc., consumer cooperative Northeast, expects 1945 purchase for the farmer more than million worth farm supplies made wholly partly finished steel. the attacks independent retailers farm goods become too insistent the GFE plans use its huge purchasing power buy goods for the farmer and sell cost. new million wind tunnel has been placed operation the NACA Aircraft Research Laboratory Cleveland. Test section the tunnel has diameter ft., sufficient for testing engines 5000 hp. more. temperatures sam- ckly ‘hile land that teel num Bars Paul 30,000 ft. can simulated. Constructed alloy especially adapted temperature changes, the tunnel supported through steel rollers concrete piers provide for movement any direction permit expansion and contraction the steel shell. Resignation the Fisher brothers from General Motors has started wave their future plans. One likely thought that they might enter the parts field. Other enterprises talked about are prefabricated housing, plane manufacture operation and automobile manufacture. Reconversion plans the Packard Motor Car Co. were made known last week the company. These plans include 200,000 cars the second year after output resumption authorized with prices about $125 below the prewar level. While out West, Fairless suggested that steel prices will higher postwar than prewar present. Basing point price steel the West Coast will crease relative the eastern seaboard base, prophesied, because increased volume the Pacific area market and with new, more modern installations reduce manufacturing costs. view the worries some the Germans must have, little surprising note the violent controversy now raging their technical press regarding priate term apply that branch metallurgy commonly referred the metallurgy". Some authorities don't like pulvermetallurgie (powder metallurgy), but prefer metallkeramik (metal ceramics) sintermetallkunde (sinter metallurgy). The Russians use "powder metallurgy", the controversy will likely resolved automatically due course. History the development and manufacture steel cartridge cases has just issued Lt. Col. Turner, who headed this work Ordnance. Production was initiated 1941 and abandoned December, 1943. Ordnance spent hundreds tillions this project, wherein securing physical properties the cases was obtained cold work. the report stated that physical properties could have been obtained heat-treatment with far less difficulty. Ordnance Association, spokesman for the Ordnance Department, has just issued report that the robot bombs England "has important military significance". that the development the Garand rifle far outdoes the robot bomb". German fighter aircraft have been sighted. They are opposed the well-publicized Bell twin-engine jet fighter developed for use. Perhaps British and American jet fighters also will tend toward single The optimism reflected Allied spokesmen has caused many war workers York State leave their jobs that manpower crisis has resulted, officials say. containing only oz. impurities 1000 lb. produced each year being made radio wave furnaces the Westinghouse Electric Mfg. Co. This pure iron provides yardstick against which the composition steel, aluminun, and other metals vital the war may quickly and accurately measured. Formed into reds about diameter, the iron used spectrographic | 1 | parre en demanding forgings finished more closely size, Springfield Armory has saved tremendous amount manufac- turing for the cal. 0.30 Garand rifle. Revision the initial machining operations has resulted use less machine tools and corresponding fewer supplied smooth and round and close the final shape, Springfield Armory has been able revise the initial machining opera- tions the barrel for the cal. 0.30 M-1 Garand rifle accomplish noteworthy savings cost. Paying few cents premium for quality forg- ings has enabled manufacturing costs (based direct labor plus 250 per cent overhead) reduced ap- proximately per cent the cost barrels made outside contrac- tors. Not only has the Ordnance De- partment been able save millions dollars but also has conserved tremendous tonnage alloy steel that would otherwise have reproc- insisting that barrel forgings IRON AGE, August 10, 1944 essed scrap turnings form. There seems have been gen- eral reluctance the part barrel manufacturers throughout the country accept close forgings. They appear afraid take chance for fear of-excessive drill runouts. They want play safe demanding heavy forging and some cases using bar stock. This policy has resulted using tremendous amount steel and mill capacity, with its at- tendant loss power, transporta- tion, man hours, machine hours, tools and tool upkeep. When the idea using close forg- ings was first considered Spring- field, the object was take chance and for any reason occasional Gun Barrels Machined Reduced Forgings ° ° FRANK OLIVER Technical Editor, THe AGE ° ° barrel was lost the drilling process through excessive runout, the loss would far outweighed the over- all savings steel, labor, turned ‘out, experience proved that over long period losses due drill runout were small that there was need for metal the forging excess that ordinarily required assure that the tungsten carbide tools used turning the barrels were always embedded the metal. Initial Experiments Initial experiments with close tol- erance forgings were first conducted barrels for cal. 0.50 aircraft ma- chine guns. vendor was found that had been making automobile axle forgings which were round and straight and had exceptionally smooth surface. small lot cal. 0.50 barrels was ordered company. These blanks were forged finished size except the two ends where sufficient metal was left for the two bearing surfaces. These barrels were singularly successful. Many machining operations were eliminated, including heavy turning and grinding operations. There was reason why barrels left with the original forged loss hat vas ere tol- ted na- hat xle and cal. his nds the ‘els ed, ing surface throughout the free length would warp firing. Not being able obtain cal. 0.30 barrel blanks forged finish size, further experiment some commer- cial blanks were turned down fin- ished diameter before drilling and reaming. The concentricity bore with o.d. obtained these barrels in- dicated that finish forged blanks could made true the cal. 0.50 barrels. this point, how- ever, the metallurgical put forth the objection that Magnaflux in- spection would not work well the forged surface and therefore light turn over the entire surface would required. Hence approximately 3/64 in. side was added the forging assure that the carbide turning tools would always cutting metal, allowing for commercial toler- ances for straightness. This allow- ance for turning, however, much smaller than before that the savings resulting from the use reduced forgings have been enormous even though finish forged barrels are not yet practical. present forging tolerances blanks for the Garand barrel are plus 1/32 in. the diameter, 0.020 in. maximum out round, and straight- ness within 0.075 in. indicator read- ing. The forged blank 1.165 in. diameter the breech end for in., reduced 0.870 in. the neck and tapering 0.750 in. the muz- zle end. The overall 24% in. held within plus in., minus take advantage the reduced forgings, necessary that they straight and round. properly Straightened, the surface that con- tacts the straightening press trunnion rolls must free from flash line marks, ridges depressions. When the blanks are received the Spring- field Armory, the first operation after visual inspection check the bar- rels for the straightness and where necessary straighten within 1/32 in. before descaling and heat treat- ment. Upon leaving the conveyorized Reduced weight forging blanks for cal. 0.30 barrel. (Mid- Barrel ready for drilling. (Bottom) Drilled and reamed, with ground bearing seats ready for turning. ° ° ° furnace* the barrels are again checked for straightness and brought *See “Special Furnaces for Heat Treatment Gun Parts,” Tue Ace, June 15, 1944. back into line where necessary. All blanks that are straightened are strain relieved prevent warpage after turning. Changes Operations number important changes have been made the initial ma- chining operations the barrel that have resulted the elimination machines with consequent reduc- tion cost well reduction process. The most radical change was the elimination the centering operation originally called for with oversize forgings when rough turn- ing operation automatic lathe was performed before the barrel was drilled. With close forgings, drilling can done directly the rough forgings soon the ends have been prevared for chucking the deep hole drillers. this change, the centering machines, six lathes and four grinders (to spot grind steady rest bearings) have been dropped. Although records previous drilling operations were favorable, was obvious that the conventional center drill hole for turning) was not only not necessary for drill- 3—Multiple tool setup Fay automatic typical turning operations the barrel. THE IRON AGE, August 10, ‘ — q 4—Use Arnold type indicator gages saves time approaching the end point plunge cut grinding operations such the one pictured. ing but impeded the single flute barrel drill, the point which actually off center. Oftentimes, its hard bur- nished surface result the turn- ing operation and contour foreign the threw the latter off and caused runouts. addition, the drill emerged from the opposite end, seldom hit the center drill hole squarely and this gave opportunity for drill breakage injury. Hence, the new setup, the barrel drill allowed start flat surface and finally emerge without unnatural ob- structions. Centers For Drilling First machining operation cut 5—Splines spaced 120 deg. apart are milled this special indexing fixture. 48—THE AGE, August 1944 off the forging length (24.220-0.010 in.) Davis Thompson duplex miller employing drum type fixture with spring loaded, wrap around clamping chain. Chamfering breech end and turning cylindrical section the muzzle end for subse- quent chucking the drillers done modified Blount center drive lathes, Fig. This machine, having chucks each end the hollow spindle, rotates the barrel 1000 r.p.m. and with carbide tools the muzzle end turned 0.710 in. 13/16 in. long and deg. chamfer placed the breech end. Through suitable linkage, single hand lever controls the feed both tools, which about in. per min. Except that the drills start flat surface, Fig. drilling with high speed steel single flute gun drills 0.292 in. diameter con- ventional operation. performed machines operating 1800 r.p.m. with feed 1.28 in. per min. The only change here that the drill started flat milled surface. Reaming 0.294 in. 0.002 in. takes place 12-spindle Steele machines, speed 110 r.p.m. and feed in. per min, Five fluted reamers are used, in. long with in. lead. Considerable pains are taken pre- pare the barrels for the turning oper- ations. From this point on, for in- stance, all subsequent operations the o.d. are located with reference the bore. First step prepare deg. bevel centers each end, done special opposed spindle Steele horizontal machine. clamped three equispaced, inde- pendent plungers each end, the bar- rel positioned end plugs which enter the bore. Upon withdrawal the plugs, the holes are then counter- sunk, Next are ground the barrel, one spot near the center, the other near the muzzle end. (See Fig. 2.) The latter plunge ground two steps and two set- ups avoid overheating the work and causing possible warpage grinding checks. The midsection plunge ground with in. wheel 0.750 in. diameter between the two grinding operations the end just mentioned. This sequence operations, involving three separate setups, assures that the steadyrests are concentric with each other and the bore. Carbides For Turning Likewise, turning performed automatic lathes, tooled with carbides. Multiple turning tools used the = ~ > > STATION Load and unload STATION Rough bore STATION Rough bore front carriage break the cut and wide plunge cut form tools come from the rear. Spindle speed 808 r.p.m. and feed 0.008 in. per rev. the maximum turned diameter 1.115 in., this corresponds sur- face speed 235 ft. per min.. Steady- rests are employed the two ground spots. (See Fig. 2.) After recenter- ing* the barrel correct distortion and peening from heavy turning oper- ations, the butt end finish ground 1.100 in. using wheel in. face Norton grinder. The wheel oscil- lated small amount during the in- feed, Fig. most small arms practice to- day, the thread the breech end milled. the Garand, deg. Acme thread called for. cut with multi-thread cutter three types machines—Lees-Bradner, Hanson-Whitney thread millers and No. 000 miller using indexing centers. The most critical dimension the tenon diameter which held within 0.002 in. This thread imme- diately becomes the locating point for the operation which form mill the top the barrel. this square nut threaded the butt end and tightened with torque wrench the same tension corresponding the operation screwing the barrel into the receiver final assembly. Form milling miller, using climb cut. fol- lowed automatic milling the hand guard grooves No. 0-8 Cin- cinnati miller, using double fixture, one doing right hand operation, the other left. Then follows inspection for straightness bore dropping through in. plug, after which the lower band bearing plunge ground under study and very Probably will eliminated. Sample bar- rels first centered rather deeply have re- tained their centers throughout the line thereby eliminating recentering. NOTE: This pilot but for restricting from passing through barre! Rough Fin. bore Fin. bore Roughream ream Fin. ream layout for Krueger auto- STATION matic chambering Burnish Z- wheel. second setup, three addi- tional spots are plunge ground—the gas cylinder lock, the gas cylinder bearing and ring clearance diameter, holding 0.0005 in. Previously, the gas cylinder bearing was ground sep- arately. Combining these operations has eliminated four machines, Spline Milling Fixture Three splines for the gas cylinder, spaced 120 deg. apart, are milled miller, using index fixture holding three barrels time. Indexing rack and pinion motion. These splines must held width within 0.001 in. less, calling for practically perfect milling saws with large col- lars accurately ground assembled arbors. Many the operations from this point relate the bore. After the ramp the breech end roughed out prior chambering, the barrel finish reamed 0.2995 0.002 in. either two-spindle horizontal ma- chine 12-spindle vertical unit. This push reaming operation. Rifling conventional operation performed two-spindle machines using single hook cutters. Chambering done either Pratt Whitney 10-spindle hand feed tur- ret units automatic vertical Krueger machines. This machine has one loading station and nine working stations. The tool layout shown Fig. The barrels are chucked and rotated. Tools not revolve but are fed vertically upward into work, the rate feed being independent each station. The Krueger machines finish all surfaces but the ramp which avoid interference with the bolt the assembled gun, the ramp tool guided from sleeve stop nut which engages the milled thread. This method preferred over piloting the tool the chamber bore since the bolt slides the receiver into which the barrel screwed. Forming the radius the mouth the ramp also done cham- bering operation, although forming the radius the intersection ramp and chamber performed drill press. Another special Krueger unit six-station horizontal machine for countersinking, chamfering and fac- ing the muzzle end length. This operation since the 60-deg. chamfer must with the bore for accuracy fire. Just before this operation, the bullet nose clear- ance milled with rotary cut small manufacturing miller two steps. Other operations complete the barrel include broaching the lower band retaining pin slot 0.124 in. half circle, threading the muzzle end the gas cylinder with ex- panding Geometric diehead Lan- dis unit and honing the chamber special vertical Carlin unit, removing only 2-3 “tenths.” After proof firing and the chamber corked and the barrels parkerized. Final machining operations are drill, ream and burr the vent hole the gas cylinder. THE IRON AGE, August 10, 1944—49 — 010 the rols ing run ned ital The ical 110 nin, in- nee are one ing are ear nge ork two and les. the 50—THE IRON AGE, August 10, 1944 LEFT OUGH bushings are taken tote boxes Johnson Bronze Co., New Cas- tle, Pa., and after pre- cision boring are placed individual slots the die cut corrugated pads that fit into the corru- gated shipping box. CENTER the operation the bush- ings are handled out and the board trays. LEFT BELOW die cut corru- gated trays shipping cartons han- dle work process. This punch press operation half bear- ings. BELOW RIGHT longer bushings, honeycomb partitions are used the cartons. This final inspection for surface defects. Packaging Process Protects Precision Parts tote box containing die cut pads separators protect parts process has helped the Johnson Bronze Co., New Castle, Pa., cut its rejection rate for bronze bushings and bearings from down per cent. Parts assorted sizes must ma- chined Army and Navy tolerances close 0.0001 in. slight scratch sufficient cause rejection and tolerance standards make difficult correct surface imperfections. Steel trays were formerly used carry products from one machining opera- tion another. Finished bushings and bearings were packed vidual cartons for shipment; never- theless rejections were costly. Then series die cut pads and separators were worked out consul- tation with the Hinde and Dauch Paper Co., Sandusky, Ohio, fit standard corrugated box required ~ ited arts ison and ent. ma- atch and cult era- ings indi- ver- and auch fit storage space. There are different pads use accommodate approximately 15,000 different parts. Each box, which holds many 525 units, individually packed each operation. While this takes somewhat longer than formerly, there has been marked reduction re- jected parts. The product packed and pro- tected for temporary storage any manufacturing operation when neces- sary. After the final operation only necessary close, tape and steel strap the carton for shipment. Cus- tomers, too, may make use the original carton their production line where continues protect the product from damage. former method packing bronze bush- ings included individual cartons that increased labor cost and offered resulting high rate rejection. Selective Copper Brazing Salt Bath Furnaces ordnance parts high pro- duction basis has been devel- oped the Industrial Steel Treating Co. Jackson, Mich. The process employs electric salt bath furnaces which not only permits the selective heating the parts brazed, but also eliminates decarburization and has reduced scrap from per cent maximum per cent compared with methods. The salt bath furnace method has also reduced distortion that the amount time and cost involved straightening brazed work has become negligible. The operation consists copper brazing two small cheek plates flat bar SAE 1050 steel (see illus- tration). The plates, approximately in. square and in. thick, are first tack welded (by spot welder) the sides the strip, the copper shim being inserted prior the welding. The parts are then placed rack which holds pieces thereby afford- ing easy manual handling. Three standard Upton electrically heated salt bath furnaces are em- ployed: Preheat, high heat and quench. The temperatures the fur- naces are controlled automatically close limits with special Upton heat Measuring and timing controls. The control for the high heat furnace holds the temperature the furnace constant level until work treated. Then, special heat mea- suring control the instrument pan- permits the operator add exact- the required amount heat for the exact predetermined time. The rack with work first placed the mouth the preheat fur- nace that the ends the work brazed are immersed the molten salt. The temperature this fur- nace held 1550 deg. When the work has had sufficient preheat, the rack transferred the high heat furnace immediately adjacent. The time that the work remains the high heat furnace and the tem- perature which the furnace held are both important. Immediately be- fore the operator parts the high heat furnace, sets the control add sufficient power hold the temperature the salt exact- 2090 deg. for min. the end time, the operator sig- nalled and the work transferred the quench. The salt quench one the rea- sons for the outstanding success the entire process. This salt quench checks the flow copper immediately and eliminates the tendency the copper blow form blob the surface the work. The work comes cheek plates are tack welded and brazed the strip with notable fine surface finish following Process features ab- sence blown cop- per, surface blobs, reduction distor- tion and simplic- ity operation not equalled other brazing processes, claimed. out the salt quench smooth excepting for thin un- important coating salt. Tempera- ture the quench, ustially held 1150 deg. F., not critical, nor too important; only necessary that the quench salt, since water oil invariably blow the copper out objectionable blobs the surface. interesting feature the proc- ess that flux not required, the salt itself flux. After the quench, the work re- hardened straightened. Rehard- ening also simple matter since the use the salt bath prevents any noticeable decarburization. Work reheated 1550 deg. immediately after the quenching that hard- ened the required Rock- well The amount straightening that required nominal due the fact that only small portion the part heated. THE IRON AGE, August 10, | ¢ 4 q OOKING the railroad situation whole, seems clear that have entered new era, that high speed traffic. High speeds affect all parts the railroad struc- ture which produce tractive effort which carry the loads service stresses. high speed low weight that the design prac- tice increasing the section in- crease its strength longer suit- able. Recourse must had new materials which are either inherently stronger which have more favor- able strength-weight ratio than the old. Insofar high speeds affect fabrication construction, the out- standing feature recent years has been the swing welding save weight and increase the joint effi- ciency. Both these practices are flux and the hope all that the new materials and the new meth- ods shaping, joining and fabrica- tion will provide needed answers many railroad problems. 52—THE IRON AGE, August 1944 Open hearth steel tremendously useful material. does good job many applications and takes pun- ishment rather easily. When need, can repaired the simplest methods. Grade castings and the carbon steel forgings are the same category open hearth plates and shapes. But with the mild steels standard passenger car can not built weighing only 110,000 es- pecially riveted construction em- ployed. Heat-Treatable Steels Turning the question substi- tutes for the popular medium carbon steel, wrought and cast, the metal- lurgical treatment many stress carrying members depends the ac- ceptance rejection the liquid quench and draw. Here well bear mind that there are cases standard alloy steels being used railroads the fully heat-treated con- dition for lightweight construction. Hence would well determine Use Alloy Battelle Memorial Institute, Columbus the cause past unfavorable expe- riences with the liquid quench see For other facets the problem postwar markets for alloy steels com- petition with aluminum and plastics, the reader referred the article, “Is Steel Laggard?”, Frederick Foote, president, Alloys Development Cofp., Ace, March 1943, 49. the deficiencies can overcome. The reason for this that heat treat- ment ordinarily the cheapest prac- tice metallurgy has offer for in- creasing the strength steel without too great sacrifice ductility. liquid quench not used, then larger additions alloy must made secure, with slower air cooling, the same strength that can secured with straight carbon lower alloy steel with faster liquid quench. The strength smaller amounts alloy are used. The new steels, which much expected, were designed for effective liquid quench, that and the scrap situation being the explana- tion their ability conserve alloy. The amount alloy which used just sufficient give complete quench for the section and cooling rate involved, and only securing the most out the quench that the small amount alloy able give the properties. Those shops which have adequate heat-treating facilities make good use the new lower alloy steels, but those which not will undoubtedly have use more highly alloyed steels. Another consideration, which seems particularly pertinent the railroads, that the drawing tem- | 3 0) q 0) ‘ 4 n de q ql Ww see the Steel 49. come, prac- thout then made the alloy The less alloy for and plana- alloy. ised mplete rate curing the give which cilities lower not more seems the tem- Steels Foreseen for Railroad Equipment harder the as-quenched condition, permit higher drawing temperature than others for required set prop- erties. Since stresses are avoided eliminated many parts, the composition should selected for such applications that high draw can used. The use small amount molybdenum and special deoxida- tion practice are both beneficial this respect. Furthermore, good prop- erties can secured with certain steels which are drawn about 1000 deg. F., which treatment used for important ord- nance weldments. Another factor that steel-mak- ing practice. means good fur- nace practice and judicious use aluminum deoxidation, particularly good toughness high strength levels, and favorable response heat treatment can obtained. This has been found particularly valu- able where welding used. Another development steel making the use which confer relatively cheap alloy steels remark- able response heat treatment. This sufficiently promising possible great interest railroading. heat treatment, these steels respond like fully alloyed steels with deep hardening relatively heavy sections, yet the soft condition, they machine very much the same carbon steels Economic Factors This situation may summarized about follows: If, after suitable study, decided that the liquid quench not suited the production important forgings and castings, improved strength can then had only extra cost for the relatively large amounts alloy which are needed. That will not impor- tant for passenger cars and some parts locomotives, but will definite handicap for freight cars. Real promise for forward step will come found that liquid quench can used, for then should possible develop low-cost light- Weight parts for rather general use, either wrought cast. this step feasible then number second- With the trend toward faster speeds and lighter structures and with inevitably stronger postwar competition from aluminum and stainless steels, the railroads would well consider the use low alloy steels, the authors contend. They point out some the metallurgical factors involved the use liquid quenched steels place the low carbon steels traditionally used for roll- ing stock construction and indicate the part that welding can play reducing weight. This digest paper presented before the semi-annual meeting the American Society Mechanical Engineers. ary issues will come up, such the best way use the cheap hardening elements, carbon and manganese, the use molybdenum raise the draw temperature and avoid minimize temper brittleness, the best melting practice used for combined re- sults, and the use intensifiers for the heavier sections. This art very potent and every effort should made the railroads use it, when feasible, reduce weight and costs. While the steels have played glorious role our war effort, there are few precautions that the rail- roads might keep mind when con- sidering possible applications. The railroads are “Carbon dustry. they adopt alloy steels, they will need equipment, control and supervision which capable han- dling alloy steels. not simple matter for whether manufacturing, fabricating con- suming, change from carbon steel asset will the past experience the railroads handling hot metal forging, heat treatment, etc. Freight Car Requirements The problem freight cars not simple that can solved the use any one steel for all types cars all types services. Each road has special problem for each car type each type service. The choice materials meet these con- ditions ranges from open hearth steel the mild-alloy high-strength steels and light aluminum alloys. Since the price paid for steel significant here, may profitable analyze the differential between the open hearth grade and the alloy grades reference freight car requirements. Only part the differential cost accounted for the alloy content the latter, important part com- ing from the melting and deoxidation practice produce fine grained, strength steel. This contrasts with the open hearth and copper-bearing grades, which have always been rim- med steel for which extra re- quired. There doubt that fine grained steel has better all-around properties than the same steel the rimming quality, but the applica- tion does not require (or justify) the non-aging steel, considerable money uselessly expended. the other hand, the mild alloy steels offer, addition, considerable improvement corrosion resistance. The effect alloy additions also fortified judicious deoxidation practice. The cost also bound reflect the re- quirements for surface finish and here well bear mind that rejec- tions the rolling flat stock are apt higher for fully killed steels than for rimmed semi-killed. These various metallurgical factors should balanced against the spe- cific requirements, and true economy dictates that metal quality bought unless really needed for the application. were found, for example for some freight cars, that the fully killed condition were not needed and the superior corrosion re- sistance the best mild alloy steels could not utilized, then the roads might well consider the use semi- killed steel with just enough carbon and the cheaper alloys raise the THE IRON AGE, August 10, 1944—53 { strength the proper level and still keep the steel cheap. regulating the rolling mill prac- tice also often possible secure improved structures meet the re- quirements. This latter type treat- ment the problem freight car bodies appears not have received the attention deserves but has been highly successful other applica- tions. one such case was neces- sary have greater strength weldable steel and yet the economics were such that every cost steel making that did not pay for itself either fabrication service had avoided. The result was definite improvement over the open hearth grade and has been highly satsifac- tory regular large-scale commer- cial production over number years. Obviously this steel does not have all the good properties the more expensive types, but this ex- perience shows that for applications which not require the ultimate forming, non-aging, and low tempera- ture properties, possible work out composition and steel making practice give superior product. taking care that each item cost steel making justified for the par- ticular product being made, the most advantageous economical material procured. Car Axle Steels The railway car axle occupies important position the history engineering materials. The standard material today medium carbon steel with relatively wide range content. The solid axle con- ventional design has long been re- garded the best (that is, most economical) for the purpose. Estimates the cost heat treat- ing carbon and alloy steel axles have come out too high for serious con- sideration, and the same holds for the cost boring out the center re- duce the weight. The hot piercing billets, for gun tubes, re- ported cheap and this, one several cases where war-induced im- provements technique bid fair apply peace-time problems, give the answer for the lightweight hollow axle which now the lime- light. metallurgical objection been raised heat treatment for axles that overheating the journal will de- stroy the properties produced the heat treatment. This indicates that steel should selected whose tem- pering temperatures, for the strength requirement, would above the usual 54—THE IRON AGE, August 10, 1944 run hot box temperatures unless anti-friction bearings are used, but this not yet the answer for the freight car. High Strength Castings Couplers for freight cars are made Grade cast steel about 70,000 per sq. in. tensile strength. At- tempts reduce the weight using 90,000 lb. per sq. in. high strength steel castings have been unsuccessful because the saving could not justify the added cost. This does not neces- sarily hold for lightweight passenger cars where weight-saving more valuable. From the standpoint de- sign, the size the part could reduced least per cent and ap- parently this would well worth- while the cost could kept line. With the foundry technique using large alloy additions and heat treat- ment which consists normalizing plus drawing, highly doubtful the requirement 90,000 per sq. in. tensile strength could secured low enough cost. With this prac- tice premium paid for alloy which not used its full efficiency in- creasing strength. Here again, how- ever, has been found that steels lower alloy content can give the re- quired strength liquid quench substituted for the slower air normalizing. Very satisfactory re- sults are being obtained both prop- erties and alloy conservation. Even the fear the foundrymen ruin- ing castings which have both heavy and light sections now known largely unfounded. present, many foundries are equipped with means for liquid quenching and have become skillful the art handling more complicated castings. Now that this equipment and experience are avail- able, re-appraisal the cast steel coupler seems order. With quantitative knowledge the effects various alloy elements harden- ability, efficiency heat treatment, should possible redesign the coupler secure the optimum com- bination weight and cost. Possibly this same treatment might also apply parts the draft gear, but there has been considerable emphasis put those parts and space limitations have already dictated the use high strength steel. There again, however, may possible reduce the initial purchase price using the liquid quench. Side frames and bolsters are also made Grade cast steel. again tremendous amount study has gone into the manufacture these parts combine design and metallurgy for the best over-all re. sults. redesigning and testing, the weight decreased and both maintenance cost and life haye improved. The engineering servative, since the maximum com- bined design stress only 16,000 per sq. in. less than one-half the specified yield point. Testing experi- ence with high tensile steel 90,000 lb. per sq. in. tensile strength cated that the saving weight was not justified the additional cost. noted that the liquid was not permitted. Considerations weight are much more tance high speed passenger cars, however, that the issue was more less forced spite increase price. Factors Welding Welding has become prominent that deserves few special For successful application ma- terial necessary study all phases the problem. These are: (1) the engineering design, (2) the steel, (3) fabrication, including weld- ing, and (4) service Obviously this group effort. these four, No. and are thought quite well handled, while Points and have not received the close and precise attention they deserve. new proposed applications which involve new engineering and fabrica- tion, Point should very capably studied, while Point must man- aged that satisfies both and Some very sad failures have occurred when was neglected improperly handled, yet that does not necessarily mean that more expensive steel needed. With persistent and conscientious study, even the tonnage steels can whipped into shape truly noteworthy job. With this technique medium steel the tonnage variety has been used for several important which are welded treated for high strength. quires study steel making with close cooperation between the facturer and fabricator establish the best practice for melt ing, deoxidation and rolling, the most economical composition inspection. keep the manufactur ing cost line, emphasis placed the points that really count and cessions are made all others. The result the cheapest that will the job and positive control necessary quality made sure. present, boiler plate mild open hearth steel the rimming rue bee all abl oth duc ste the ect att loc ste ste sti all re- ng, the have alf the experi- 90,000 was cost. quench impor- cars, nore ma- udy all are: (2) the weld- ements, ort. thought Points close which fabrica- capably man- and steel tonnage ith this nganese been with user most proper ufactur- laced and con- rs. The hat will mild ing recent years, however, there has been some interest the use alloy steel for boiler plate, presum- ably secure higher pressures with- out adding the plate thickness, otherwise take advantage re- duced weight the shell. This would appear perfectly logical step take along with the use welding for boiler fabrication. the obvious answer the problems embrittlement around rivet holes and leaks high pressures. The using high steam pres- sures well known, and any serious attempt take advantage them locomotive construction clude consideration high strength steel well welding. The brittle ship experiences have caused some question welding not being pushed too rapidly for rail- roading. There nothing wrong with welding ships done properly and the design right and the steel properly made. There can plenty wrong with welded ships the design does not allow for stress dis- tribution and the steel inade- quate handle the somewhat un- orthodox (that is, unsuspected) stresses the temperatures which these ships have broken up. Welding applied boilers differs from the ship situation that when stresses are applied, the temperature raised that low temperature brittleness avoided. course this does not hold for out- door structures for parts which cool down winter dangerous temperatures. Examples such fail- ures are the so-called brittle bridges Belgium, made basic bessemer steel, and the hydrogen storage tank Schenectady. The obvious step take improve the situation, far steel concerned the failure, apply properly killed steel which does not become too sensitive winter climates. This merely matter applying metallurgical principles, long known, but often neglected. Incidentally, another advantage the liquid quench and draw for heat treating steel, decided improve- toughness low tempera- tures. This would hold for couplers, draw bars, and the like which may highly stressed low temperatures. One metallurgical development the war can cited that may have really revolutionary effects the railroad industry—that the de- velopment alloys for high tempera- ture service that bid fair make the gas turbine feasible. When this accomplished may expect that locomotives using that type pro- pulsion will come for comparison with existing types. oil re- fineries, with cheap waste fuel available, the gas turbine economi- cal when the operating temperature the neighborhood 1000 deg This temperature not too high for the older alloys, but the efficiency too low when more expensive fuels must used. The new materials indicate possibilities carrying the temperature high levels which important improvement may expected. Recent tests creep strength indicate values well over 12,000 lb. per sq. in. for creep rate per cent per 100,000 hr. 1350 deg. This represents marked advance high temperature alloys. soon design and con- struction, and experience operation, have made possible utilize the new materials full efficiency, the gas turbine drive may take prac- tical significance for railroad service. Shaper Clamped Work Machines ~ < ABOVE LOSE-UP view the shaper head, showing the pad the inner the base being machined. Clearances necessitate use bent shank tools large overhang. Clapper boxes are mounted auxiliary cross slide with crank for feeding the tools into depth. LEFT HIS special Rockford Hy-Draulic shaper was dev