The Iron Age 1944-08-17: Vol 154 Iss 7

fort fea- nended. CENTERS VAN DEVENTER President and Editorial Director BAUR Vice-President General Manager ° Editorial and Advertising Offices 100 East 42nd St., New York N.Y., U.S.A. Johnson, Market Research Mgr. Hayes, Production Manager. Baur, Typography and Layout ° ° Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. ROBERT BLAIR GIBBS Cleveland Pittsburgh 1016 Guardian 428 Park Bidg. Philadelphia Chicago Chilton 1134 Otis Bldg. 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. 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH Vice-President GEORGE GRIFFITHS EVERIT TERHUNE Vice-President VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE THOMAS KANE HARRY DUFFY CHARLES HEALE ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents. Copyright, 1944, Chilton Vol. 154, No. Editorial Successful Postwar Technical Articles The Right and Wrong Time Study Computation Ford Biggest User X-Ray..................... Resistance Welding Protective Coatings for Aircraft Parts................ Non-Ferrous Alloy Blanking New Equipment Features Personals and Obituaries Fatigue Cracks This Industrial Week News Industry News and Markets Midwest Manpower Shortage Non-Ferrous Metals News and Developments Non-Ferrous Metals Prices; Scrap Iron and Steel Scrap News and Finished Iron and Steel Steel and Warehouse Semi-Finished and Tool Steel Prices Steel Pipe and Tubing Prices Pig Iron and Coke Railroad Material and Stainless Steel Prices Ferroalloy Prices Index Advertisers 100 102 104 107 109 162 166 168 170 172 174 176 177 178 179 180 181 182 265 IRON AGE August 17, 1944 } | ° ° ° | ° ° The Hydro-Foam principle Mahon Dust Collecting Systems the key their exceptional effectiveness service. Even the finest dust particles —the most dangerous workmen and work—are captured and per- manently trapped under water. Control this foam action has been achieved only after many years continuous research Mahon engineers. Three separate stages dust elim- ination are accomplished. means powerful suction-ex- haust fan—the only moving part— the dust-laden air drawn from working areas into the unit where heavier dust particles drop grav- THE DETROIT removed the MAHON patented FOAM CONTROL ity into the sludge tank, located the base. Still carrying consid- erable volume dust, the air stream then enters battery accelerators, which direct the air downward high velocity, forcing the bulk the remaining dust into the treated water the sludge tank. This impinging action aerates the sludge tank solution and forms bed foam above the water line. (See illustration right.) the air stream passes through this foam bed the more minute dust particles are “smothered” and settle the bottom the sludge tank with the heavier dust previously removed. Air emerges from the exhaust stack thoroughly cleaned. ACCELERATOR A, Ser 4 4 Mahon Collectors are practically and every are interested vanced method dust elimination, greater effectiveness, ity and economy have been proved write for descriptive Complete Finishing : - Manufacturers Metal Cleaning Machines Rust Proofing Machines Hydro-Filter Spray Booths Ovens All Types Filtered are every purpose. thi ination, AGE ESTABLISHED 1855 August 1944 ° VAN DEVENTER President and Editorial Director BAUR and General Manager DIX Manager, Reader Service ° Editorial Staff Technical Editor........ OLIVER Commercial Editor, CAMPBELL Associate Editors WINTERS TRUNDLE ALBIN Editorial Assistants SCHIEN WILLIAMS ROGERS Regional News and Technical Editors LLOYD Pittsburgh 428 Park Bldg. POST Chicago 1134 Otis Bldg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press MacDONALD Cleveland 1016 Guardian Bldg. BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT McINTOSH Cincinnati PENLEY Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle Successful Postwar Selling have pretty well licked the problems production. Given product, however complex, and our engineers will tell how make the most economical and efficient way. What will need after the war someone tell how sell similar fashion. There still plenty slack taken out sales and distribution. Perhaps should thankful for this condition for did not exist there would opportunity for improvement. present are the same position with regard merchandising and marketing was the man who had all the bad habits and was thankful that had many things that could give the necessity arose. see it, there going strong trend towards specialized sell- ing the postwar days. will forced upon from the standpoint self-preservation. Also from the standpoint reduction sales costs. Specialized selling something like specialized medicine. Its prac- titioner must adept who knows more about his product than his customers prospects do. That has not always been the case the past, for too frequently machines, and materials have been bought rather than sold. Bought because the user knows more about the product than the man attempting sell it. adept and know more about what one selling than the customers and prospects, the salesman cannot attempt “all around man.” must concentrate fewer products and upon know- ing almost all about them. That quite job because next impossible for man know all even about such simple things lead pencils frying pans. one, for example, has ever been able tell why they not make rectangular frying pans which fit slices bacon better than round ones. know almost all about the products that one has sell the first step. The second know almost all about the products that enter into competition with what one going try sell. The third step determine the points superiority your product. The fourth learn how express this superiority the prospective customer. But these things, turn, are not enough. The super-salesman tomorrow who specialist must also know nearly all about his pros- pects’ needs with respect the product has offer. Having this knowledge and that his product and how will serve these needs better than any competitors’ product, our 1945-1946 model salesman will not have read any books sales technique order town. For you are prepared show man who has definite need that you can fulfill better than anyone else, your sale made before you ring his ddorbell. Most the sales effort involved this super-selling will done home, the sales manager and his staff, rather than the customer. The sale merely the terminal reached after laying the ties and the tracks. It’s easy once you have laid the road bed. | | hing The ground coat these Inland Enameling Sheets free blisters, pin holes, burnt-through spots Inland Enameling Sheets are made fit your needs! When you specify Inland metallurgists and mill men ing Stock you are certain getting who are particularly experienced sheets that have the exact proper- production enameling stock ties and finish fully meet ready serve you. ex- quirements. They give tremely careful selection raw mate- tight adherence, uniform surface, special processing and thorough extra flatness, accuracy they can definitely help superior drawing and forming prop- achieve higher quality your erties and unvarying enameling enameled parts and products. Con- qualities that keep production going sult Inland regarding your enameling smoothly and reduce costs. sheet today! Bars Floor Plates Piling Plates Reinforcing Bars Sheets Strip Structurals Tin Plate Track Accessories INLAND STEEL COMPANY News August 1944 large developing X-ray thickness gage for checking sheet steel thickness comes hot from the rolls. The device follows the pattern counting tubes used for measuring the thickness forged cylinder walls. employs X-ray tube side the swiftly moving hot steel sheet and the other side ionization measure the intensity transmitted radiation. quarrying alunite ore the Salt Lake City plant has been closed down because excessive stocks Marysvale, Utah. refined the Olin plant Tacoma, Wash. Giant bombers now being used not require the long runways that were pated. Instead wheel brakes, reversible pitch propellers have been developed brake the plane rapidly, easily and safely. Data tentative uniform method specifying alloy steels have been issued the S.A.E. and the American Iron and Steel Institute. This method springs from engineering philosophy selecting steels the basis hardenability index tensile strength, with only corollary reference chemical compositions. The new data are applicable standard fine-grain steels, and include the 4100 series from 0.30 0.50 4340; 4620; and the 8600 and 8700 series from 0.20 to. 0.50 For other standard steels similar data are now being prepared. One the earliest civilian industries swing back into production will sweepers. The Hoover Co., for instance, has for some months been busy one factory Canton rebuilding old sweepers. Another factory Ohio River near Marietta being equipped for the manufacture new sweepers. provide heavier and better fighter than the Airacobra, the new Bell Kingcobra was developed. Although differing only slightly appearance from its prototype, the about 700 lb. heavier than the 7650 lb. and has span more than ft. Chief change the power plant. The has two-stage Allison, 1500 which gives greatly increased power and speed over the single-stage Allison which powers the P-39. Service ceiling the new plane 35,000 ft. Although the general impression that E's have been granted only per cent the nation's eligible plants have received the award the tw@ years since its institution. the second anniversary the presentation first award, Aug. 10, was announced that the award had been granted only 3097 plants. New emphasis production and military and naval project program $100,000,000 have created additional manpower difficulties for West Coast joint meeting between Army, Navy, business and labor representatives Seattle, was estimated that 37,000 workers are needed the Puget Sound area immediately. From the meeting emanated program which specified that civilian construction repair jobs must postponed indefinitely and that direct war and military will graded seven brackets. Neither manpower officials nor labor vill supply workers those the second and lower brackets until the first Union factionalism has been responsible for the delay settling the strikes Motors. Sentiment favor repealing the no-strike pledge the UAW's convention next month growing with Walter Reuther, Richard Leonard and Richard Frankensteen jockeying for the position first vice-president. tractor production which Graham began make 1941 and output line implements with this tractor. q * qT spots > a would dispute the statement that accuracy computation, well precision the measure- ment time values, absolutely es- sential effective time study work. Yet the entire area computation, including the application allow- ances, the determination the level- ing factor, and much the formular- ization which could used sim- plify time study work, has been rela- tively unexplored. any, industrial engineers For additional information time study procedures, also see “Planned Time Study Standards, THe Ace, Oct. 29, 1942, 34. While there have been great num- ber texts written recent years, most the work done the field has been directed towards the de- velopment new methods the re- finement existing methods, with the objective increased accuracy the measurement time values. The need for exacting precision the de- velopment time standards for vir- tually every type man and machine performance has been expounded the leading engineers the field. Precision has been emphasized the extent making micro-motion film analysis the time values ele- mentary movements requiring 0.001 min., less. This progress measurement, however, has not been matched equal progress the manipulation the time values measured and their synthesis into time standards. many classes work, startling may seem, the accepted methods computation often result serious errors the determination the final standard. For example, the widely accepted practice adding allowances selected job cycle times order take care necessary op- eration delays, such tool mainten- ance and tool change, clean time, operator’s personal allowances and fatigue, arithmetically incorrect. The most widely used method de- 60—THE IRON AGE, August 1944 The Right and Wrong Time Study Computations ° DAVID ANDERSON Industrial Engineer and ARTHUR HANSEN Head Standards Department, Bulova Watch Co., Woodside, ° ° ° Although time study procedures are almost always preceded precise measurements time values, much this work has been wasted faulty allowances for personal and fatigue delays and machine maintenance. This article which will followed two others, "Simplified Time Study Computations" and "The Proper Determination the Leveling Factor Time Study," discusses accu- rate calculations and applications for correct time allowances that employees working under incentive systems can readily understand. termining the leveling factor relatively inflexible procedure and does not give sufficient consideration the fact that the relative impor- tance the factors skill and effort determining job output are not always the same. different jobs, these factors may each contribute very different percentage the effec- tiveness the operator’s perform- ance. may seem incredible that the face such exacting precision has been demanded time study technique, such looseness the han- dling time values, and the com- putation and application allow- ances should exist, but is, never- theless, true. Computation Allowances The present method handling allowances widely used time study computations follows: study made determine the amount necessary delays which are generally incurred particular job class work during average day. These may cover oiling and warming equipment, sharpen- ing changing tools cutters, clean time, etc. Similar figures are established cover productivity losses result fatigue. Each these times divided the total working day arrive percent- age allowance. means this method, tables fixed percentages allowances are established cover personal allowances, fatigue allow- ances and unavoidable delays. This method has been described quite some length many recent texts* Barnes, “Motion and Time Study,” pp. 272 and 285. “Time Study Engineering,” Lowry, Maynard “Time and Motion Study,” 252. time study technique, and widely used most time study procedures today. William Schutt, his book “Time Study Engineering,” goes in- some detail describing the nor- mal manner which allewances should determined and applied. page his book, says, “Determining Definite Time Allow- ance.—If the personal allowance should definite time, say min. per hr. day, and the fatigue allow- ance min. per hr. day, the first thing you must determine what percentage day min. is. been and two accu- that Each total this ges cover allow- This quite texts* Study,” ng,” merten, widely edures book nor- wances ed. Allow- min. allow- first what is. are considering hr. day. know there are 480 min. that time. Therefore, min. 24/480 day What percentage min. the same procedure? After the percentage obtained, simply multiply the selected time precisely the same manner under Percentage Allowance.” essence, the procedure used simply this: The number minutes allowed each category first determined and then expressed percentage the total working day. The allowance then made adding this per cent these percent- ages the effective working time (selected job cycle time). article that: (1) The method generally used arriving the percentage allow- ance that added the nor- mal working time, and that its use results gross errors the standards which are set. (2) Even the proper method were used determining the percent- age allowance, this method add- ing percentages the normal work- ing time not desirable since its use results the need for different percentage cover the same num- ber minutes allowance each class work, and many individual jobs within the same class. (3) Another method, much simpler understand, and explain em- ployees incentive programs, and more accurate, can easily used. essence, the principal fallacy the usual method making allow- ances, which has just been described, that since the effective actual work time less than the total working day, per cent com- puted the total working day, and then applied much smaller part the total working day, namely the effective actual working time, longer equivalent the number minutes allowance originally in- tended. This becomes plain when realized that the total working day fixed, and the effective work- ing part the total working day varies, according the number minutes allowance required the job. Therefore, any fixed percent- age the total working day this variable working time cannot ap- plied with resulting fixed number minutes allowance. Thus, can seen that the plant policy allow min. per day for personal allowances certain classes work, then this min. will always different percentage the effective this working time, depending how much the total working day the effective working time is. This will, course, different for every class work. Regardless the class work type allowance, this logic holds true whenever fixed number minutes per day expressed percentage the working time. If, addition the personal al- lowance, required allow for certain delays, such clean time, ment, and for time lost through fatigue, the effective actual work- ing day further reduced and the per cent that each these allowances the actual working time, further increased. The error, there- fore, which would result from the use fixed percentage allow- ances based the total working day, would larger: The following extract from study semi-automatic equipment, one many made the Bulova shops will illustrate the extent which many standards may thrown off the accepted methods making allow- ances the cycle effective work- ing time. During the hr. average working day, the following allowances were made for particular class work: Min. Per Cent Type Allowance Delays, handling, ...... Tool maintenance, warm up, 162 The normal time per piece for the operation under study was 0.15 min. The generally accepted method ap- plying the allowance follows: Allowance, per 0.045 min. Standard time min. The hourly production then com- puted: min. 195 min. 307.2 pieces per hr. This figure now established the task. The daily hr.) produc- tion this basis, would, be: 307.2 2764.8 pieces per day. However, the correct computation should be: 540 min. (total day) —162 min. (allowance) 378 min. effective work time per hr. day The selected time 0.15 min. determine the daily production: 378 effective working min. min. 2520 pieces per day. The standard that would set the usual method applying the 0.15 THE IRON AGE, August ‘ving fs ne yz y, b | en, co. 7 7 a Conversion Per Cent Allowance Cycle Time into Minutes per Hour, and Per Cent Total Time (This table may used determine the percentage the total work day, and the number minutes per hour which are actually allowed percentages allowance made cycle Per Cent Allowance Cycle Time Per Cent Allowance Total Time Allowance Minutes Per Hour Per Cent Allowance Allowance Cycle Total Time Time Per Cent Allowance Minutes Per Hour 20.64 12.38 per cent allowance (30 per cent) the normal working time per piece (0.15 min.) would have been 2765 pieces per day, against 2520 pieces per day, which what the actual standard should be. this case, the percentage error would have been 9.7 per cent. This error sufficiently significant upset the production schedule Standard Allowances Per Hr. (In Standard Produc- tive Minutes Per Hour Engraving Spiral drill well wipe out most the in- centive possibilities the job. This is, course, especially true when dealing with equipment where the machine time major part the total cycle, and, therefore, large extent the controlling factor limiting the rate output. important that the nature the error clearly seen. the Semi-Automatic Equipment Personal Fatigue and Consistency Clean and Tool Care and Maintenance Mach case illustrated, the productive day is: 540 min. (total day) —162 min. (allowance) 378 min. (productive day) This means that for each 378 min. actual work, additional 162 min, must allowed. But when per cent arrived expressing 162 min. per cent 540 min., and then add this per cent 378 (which actually done when adding the cycle time), 162 min. are longer allowed, but only 125 effect this means that for each 540 min. worked, 162 min. will allowed. This, course, not what intended. What meant that for each 540 min. total work time the job, 162 min. tive time must allowed. ex- press this allowance the productive time, the computation must based the formulariza- tion: 162 min. allowance time 42.9 per cent min. effective work time The result the incorrect compu- tation the standard the use improperly computed cycle time al- lowances will raise havoc with the standards the factory, violates one the cardinal prin- ciples time study engineering— that is, consistency. One the unique characteristics the usual method establishing fixed percentage cycle time allowances, that the error creates the standard small those operations which call for relatively small allowance, and very significant those operations requiring large allowance. order clarify this, assume that there are two operations, each having work cycle time 0.20 min. One bench operation requiring min. allowance for personal needs, and min. allowance for fatigue, per hr. day. The other spindle tapping machine, requiring addition the min. allowance for personal needs and min. for fatigue, additional allowance min. for machine warm up, daily cleaning and oiling, and change taps which break. The usual allow- ance cycle time method would in- volve the following: Semi- Bench Automatic Operation Tapping Personal and fatigue, min. Tool Percentage work day job cycle time, 0.20 Standard time ...... 0.23 0.26 Hourly production ...... 261 231 Production per hr. day. 2350 2079 tua Pers Too! m Effe Sele ™ Pro Err 24 2.92 1.75 21.87 13.12 tiv 3.85 2.31 22.48 13.49 4.76 2.86 23.08 13.85 5.66 3.40 23.66 14.20 6.54 3.92 24.25 14.55 7.41 4.45 24.81 14.89 9.09 5.45 25.93 15.56 9.91 5.95 26.47 15.88 10.71 6.43 27.00 16.20 11.50 6.90 27.54 16.52 13.04 7.83 28.57 17.14 14.53 8.72 29.58 17.75 15.25 9.15 30.07 18.04 15.97 9.58 30.56 18.33 16.67 10.00 31.03 18.62 17.35 10.41 31.50 18.90 18.03 10.82 31.97 19.18 18.70 11.22 32.43 19.46 19.35 11.61 32.88 19.73 20.00 12.00 33.33 20.00 Auto-drill and co-bore........| 46.0 126 62—THE IRON AGE, August 17, 1944 day The correct standard should ac- tually be: Semi- Bench Automatic Operation Tapping Work day, min. ........ 540 Tool Effective work day, min. 459 378 Selected job cycle time, 0.20 Production per hr. day 2295 1899 Error standard 2.4 per cent bench operation per cent, semi-automatic tapping opera- tion. Thus, the effect this re- duce almost negligible the incen- tive possibilities the operations operator runs ma- chines this battery high precision millers. The allow- ances required are usually high and call careful treatment. that generally most need them—the operation machine batteries and equipment having high per cent down time such multiple spindle, drilling, counterboring and tapping machines, and others that class. Here the incentive possibility usually limited fixed machine speed, and the operator must first have overcome the disadvantage time study error before reaching incentive earnings, the chance real incentive limited. small ma- chine hand operations, the other hand, where the allowance usually greater than per cent, the error not great, and the op- erator can usually reach high in- centive levels. Reviewing the conclusions that have been drawn far, ob- vious that those individual firms and management consultant organizations who have gone the extent pre- paring elaborate fixed percentage covering personal and fatigue allowances made cycle time, have based their work very fallacious premise. The surprising element this en- tire situation that this fallacy the determination and application allowances should not have been un- covered before. From time time, there seems have been some reali- zation the field, that the present not all that should be. re- cently last year, the United Elec- trical Radio Machine Workers America, one the largest indus- trial unions accept time study basis for incentive systems, made survey time study methods. booklet prepared for its membership, the union seems express some awareness the fact that the cur- rent method making allowances defective, and page the book- let, attempt outline slightly different procedure for applying allowances was made. However, the method which they recommended essentially the same method being used present, with some minor variations; but the same error in- herent the computations. The basic fact which seems have been missed those who have examined the pres- ent method determining allow- ances that fixed number minutes can ex- pressed fixed percentage, this ing work time. interesting note that sev- eral instances, unquestioningly has the usual practice making allow- ances been accepted, that some texts the data are presented such manner that the author arrives the correct computations, but realizing that the standards which would set these figures are different from the ones which would set the generally used method, proceeds re- ject the correct answer and recom- mend that the computations made the usual manner.* William Schutt, “Time Study En- gineering,” 376. Barnes, who has made some very excellent contributions the field motion analysis and time measure- ment, his book, “Motion and Time Study,” pages 278 and 285, out- lines the usual method determin- THE IRON AGE, August 1944—63 min, min, per 162 and . are min, each what tiple for low- ing allowances. Through the error thus created the standards which would established this proced- ure, negates many the advan- tages derived through his extremely methods time measure- ment. Determining Allowances There are, course, several simple ways which allowances can made the work time, and still allowances, has been found that the following method sufficiently flexi- ble cover most conditions. The method itself extremely simple execute, and based the fact that every job, the standard which set simply calls for certain normal (leveled) rate effort and skill for fixed number minutes per hour. The number effort re- quired simply the total (60 high precision finish turning machines using diamond cutters, all holding tolerances 0.0004 in. correct. However, there are many disadvantages inherent the use this method. Correctly applied, allow- ances cycle time would often re- quire the use different percent- age cover the same number minutes allowance, depending the amount total allowance made. This condition extremely difficult tive system, and makes the task the time study engineer, anxious enlist the cooperation employees working under standards, even more difficult. easy task explain two different operators why one them should have per cent allowance cover her personal needs, and the other per cent al- lowance, even though both percent- ages cover the same number min- utes personal allowance. order overcome the ambiguities and dif- ficulties involved using cycle time 64—THE IRON AGE, August 1944 min.), allowance. This called the “standard productive min- utes per hour.” computing allowances this method, the total number minutes allowed first determined. This number minutes then sub- tracted from the number minutes the total working day. The re- maining time the effective work order prorate the ef- fective working time over the entire day, the following computation can made one setting the slide rule: Effective work time Total work time Standard minutes per hour. For example, the first sample study illustrated, the required amount allowance was 162 min. per day, and the effective work time was 378 min. order prorate this over day: 378 min. effective work time 540 min. total working day Standard min. per hr, (SMH) The selected job cycle time this operation 0.20 min. The hourly task, is, therefore, 210 pieces per hr. 0.20 Selling the Standard Bulova, where per cent the production employees are work- ing under incentive system, has been found that this method ap- portant advantages addition its accuracy. explaining time study standards employees, much more effective show employee that she has been allowed 120 min. per day, rather than tell her she has been given per cent allowance the selected job time. Having allowance minutes makes very definite impression the mind the operator and helps make easier sell the standard the employees. has been found very effective set allowance charts such the one illustrated herein order both standardize and dramatize allowances. Having allowances available this form for presentation provides quick and effective answer the question asked frequently opera- tors being placed under standard: “What you think am? robot!” The operator able visualize terms minutes per day the amount time available her for the vari- ous factors allowed. The time study engineer making this explanation can then point out the operator, the incentive possibilities the job that are inherent the allowances them- selves, exclusive any incentive that may earned through increase speed skill. The standard minutes per hour which set base for comput- ing production constant minder the foreman that the ef- fective work time his department far less than the available time and constant challenge his sible all job interferences. Finally, simple and uniform scale allowance can easily lished, doing away with complex charts that often cause con- fusion and misunderstanding. i q ent of work- has ap- study much 120 cent time. makes the make the tive the both this des the opera- ndard: ‘obot!” lize vari- study nation or, the b that them- that hour ef- rtment time nis in- pos- scale estab- nerous Ford Biggest User X-Ray all the war plants throughout the country, Ford the No. user X-ray industrial equip- ment, providing radiation voltages from 5000 1,000,000. Today General Electric units are inspecting thousands dif- ferent parts for war equipment, in- cluding those for the B-24 Liberator bomber which now coming off Willow Run assembly lines the rate one hour. More than 125 per- sons are employed the various Ford X-ray departments and the company maintains school teach civilian operators how BELOW million-volt X-ray unit the steel foundry used examine cast crankshafts for the Ford 500-hp. tank engine and also heavy castings for the M-8 light armored Two specially built flat cars, with lead covered deck about ft. square, are used carry large num- ber prepared castings into the X-ray room for ex- During the other flat car reloaded with castings and necessary films and markers. posure. handle X-ray equipment and proc- ess films. Ford has two G-E million-volt in- dustrial X-ray units which routinely inspect min. the same number steel parts that required hr. with low-powered apparatus. One these units the $27,000,000 air- craft engine building the River Rouge plant, which has been turning out 2000 hp. Pratt Whitney engines and the other, pictured, the new steel foundry. The million-volt unit the aircraft engine plant used X-ray heavy steel castings, turbosu- percharger parts and wide assort- ment bomber and glider castings. — “y the Ford electric furnace building 400,000-volt G-E X-ray unit used for the examination heavy steel and alloy castings for the B-24 bombers. top right, centrifugally cast pivot hinges for the land- ing gear the plane are shown being radiographed four time from two different angles. The castings are placed manually specially constructed cart having four individual sections which can any desired angle. When the castings are place the lead-lined doors are closed and the X-ray pictures made. TWO 140,000-volt X-ray units are used the Ford aluminum foundry radiograph repair welds cylinder heads for the Pratt Whitney engine. The exposure made lead-lined steel cabinets, which about ft. long and ft. high. Pneumatically-operated doors are closed during the exposure protect the workers. While the exposure being made, the technician prepares another cylinder head for examination. THE IRON AGE, August 4 Resistance Welding Aircratt The Douglas Aircraft Co. has speeded production develop- ing multiple spotwelders for the tack assembly stainless steel ammunition boxes and chutes, and index spotwelder for landing flap deflectors. Collet type dies have been developed for the con- centric alinement tubing for flash welding. This article sub- stantially presented the April meeting the American Welding Society. fact that re- sistance weld- ing was already well developed science the time the aircraft industry became interested its possible applica- tions aircraft fabrication, may seem presump- tious for the aircraft industry boast about “new” developments and production methods. Although the ap- plication resistance welding air- craft has during the past years increased from nothing its present extensive use leaps and bounds, the aircraft industry today lagging behind the automotive industry the use resistance welding for accom- plishing mass production. Thus apparent that have developed lit- tle nothing that would value highly developed mass production industry. Rather, have arrived our present limited mass produc- tion refining old methods make them fit the vastly greater quality requirements the aircraft industry. Likewise, apparent those who have been involved the devel- opment methods used aircraft production resistance welding, that although the automotive industry had already developed equipment and methods high degree for its ap- such development was soon found negligible value the aircraft industry. The few who have been the aircraft industry since the first resistance welding applica- view the IRON AGE, August 17, 1944 PERRY Assistant Process Engineer, and HAGER Weld Tooling Design Co-ordinator, Douglas Aircraft Co., Inc., Segundo, Cal. before could tions were tried fully under- stand the reasons why peared going process hit many snags safely nomically used aircraft. The novices aircraft resistance welding see only the present highly refined, electronically controlled equipment, which owes its development the re- quirements aircraft; thus they know little the growing pains dur- ing early development. Automotive Welding Practice the automotive industry, all de- velopments were the direction greater production lower cost; the main quality requirement was that the parts should hold together. De- sign for 100 per cent joint efficiencies was unheard and wholly unneces- sary. The only material was steel, and the use lead, putty, grinding and paint made even the surface ap- pearance after welding matter little consequence. steel has very wide plastic range, almost any combination current, pressure and time will make weld which will meet the low quality and strength requirements the automotive in- dustry. contrast, the requirements aircraft are exacting that, not only automotive resistance welding equipment unusable, but personnel who have trained that type equipment used the automotive industry require additional training before attempting aircraft work. addition the immense advan- tage comparatively low strength and quality requirements, the auto- motive industry also had the huge quantity production demands which make special tooling not only econom- ical but absolutely necessary. The cost, spread over millions units, was small item compared the savings man hours. Very large sums money were spent each year develop automatic multiple se- quence welders which would complete- spotweld flashweld, within one minute, entire automobile body chassis. Limited Tack Welding highly improbable that such mass production methods will ever applicable aircraft production; even the future ship made en- tirely stainless steel, the most favorable spotweld material, will unsafe use multiple sequence weld tooling for more than tack as- sembly purposes. would im- possible maintain tip size and shape, and current distribution ac- curately enough insure high ef- ficiency joints made either mul- tiple sequence welding, nor would the cost such complicated tooling justified the quantities involved. Before the demands war stepped aircraft production previously unheard levels the only spotweld tooling used was that required hold contours while tacking, and hold dimensions parts for interchange- ability. Relatively tooling costs were incurred merely for the purpose saving labor hours; such tools were expensive and labor was that time both plentiful and cheap. 18-8 Best for Multiple Welding Tests made the Douglas Se- gundo Plant early 1934 led conclusion that series multiple ining ngth huge vhich nom- The the large year se- one spotwelds aluminum alloys could not produced meet consistency requirements. With alloy which has extremely short plastic range and low resistance, imperceptible vari- ations electrode contour, pressures and surface resistance are enough disturb the current distribution that one two weld joints may heated below the plastic range and fail weld, while the other may heated above the range and blow out. Any series parallel spotwelding aluminum alloys will produce very high percentage duds. For this reason, well the huge current values required for single spotweld, multiple tack welding this material ° ° 2—Shown this Multiwelderfor the nose ammunition box are: aluminum alloy core expanded load parts; 2—air cylin- der expand and collapse core; series-conductor bars made No. 4—reaction and conductor plates copper; 5—unit air cylinders bring electrodes contact with the work; from the welding transformer; push button for weld- ing impulse; pressure switch; four-way air valve. ° ° impractical. 18-8 stainless steel, which has electrical resistivity eighteen times that dural, and has the wide plastic range steel, offers the best possibilities for multiple welding. Early 1941 the Segundo Doug- las plant was committed the mass production 1000 A-20 bomber nose assemblies. Two stainless steel am- munition boxes, Fig. were installed each nose, and half again many spares had been ordered. total 3000 this item offered the first opportunity justify the cost tooling mass production basis. Tack Assembly Multiwelding Preliminary tests showed that with uniform electrode pressures and cur- rent distribution, spots made parallel were all sufficient uniform- ity and strength for tacking purposes. the evidence test samples, approval was obtained for the design and construction the first “Multi- This machine was serve aire craft nose ammu- nition box tack assembled Multi- welder. guinea pig determine possible future application this type as- sembly tooling. The design was based upon the practical consideration accomplishing the greatest time-sav- ing possible without excessive tooling expenditure. time study showed conclusively that the jig tack weld assembly time was per cent the total spotwelding time equivalent assemblies; therefore, the greatest time-saving could accom- plished minimum tooling cost designing the Multiwelder make simultaneous tack welds the mini- mum number locations required make rigid and accurate assembly. The small time required for “sewing up” the tacked assembly automatic repeat spotwelders made imprac- tical accomplish more than tack assembly the Multiwelder. the resulting Multiwelder, Fig. seven detail parts were simultane- ously tacked together points means two sets oppositely placed, parallel-series connected elec- trodes. 3—Nose ammunition feed chute after welding. Only spots are re- quired for tack assembly. THE IRON AGE, August 17, 1944—-67 most ¥ mul- would tweld ange- Se- LEFT welder loaded with parts for tack assembly ammunition feed Loaded core ready swing welding. RIGHT 5—These tack welded center ejection chutes are welding. BELOW 6—The cores are loaded and ready swing into position for tack welding this dual Multiwelder for the ejection chute, showing: and 2—Assembly cores expanded for loading; 3—reaction and conductor plates; 4—insulated center reaction plate; center plate, dual, oppositely expanding air cylinders; copper series-conductor between dual cylinder electrodes; clips hold chute mounting clips place for tack welding; 8—air cylinder for operation clip locating holders. | 68—THE IRON AGE, August 1944 A “charged fixture.” The two reaction plates which support the unit elec- trode cylinders are made heavy copper plate and also act bus bars for current distribution the trodes. Mallory No. alloy elec- trodes, with Elkonite inserts, are screwed onto the air cylinder piston ends, and connected electrically the charged reaction plates means flexible braided copper leads. The unit air cylinder in. diameter neoprene diaphragm type which gives 175 lb. electrode pressure air line. All cylinders are commonly sures will equalized. The rigid cast aluminum core accurately sized the minus side dimensional tolerances allow use details within the tolerance range. designed roll swing between the reaction plates for weld- ing after detail parts are loaded the open. Bars Mallory No. alloy pass through the core between oppositely located unit cylinder elec- trodes, serve anvils for these electrodes, well conductors place them series. each series electrode circuit, the current passes from one electrode through face the Mallory anvil and out the other interface the oppositely placed electrode; thus making welds series symmetrical points the assembly being tack welded. All these series electrode circuits are paralleled common connection the air operated electrodes each reaction plate. After applied \ x * # 4 ally elec- heavy bars elec- are piston the ans The ameter gives pres- ore side use erance weld- No. etween elec- these series passes the two points welded. its are each pressure brings all electrodes con- tact with the work, one timed impulse makes all tack welds simultaneously. Rate Production One operator was able turn out tack weld assemblies per hour. comparable job, then being made conventional tooling, required two men produce three boxes per hour. two these conventionally pro- duced boxes were identical, while all boxes produced the Multiwelder were identical and interchangeable. men were lost the military forces and women were used for re- placements, the Multiwelder tooling was extended include any stainless steel assembly which had the neces- sary production quantity the re- quirement interchangeability. Ad- ditional 18-8 parts, and Multiwelders developed for their production are assemblies hitherto impossible were produced inexperienced women op- erators who seemed like and read- ily fit into this type assembly work. Labor-savings resulting from this practice has been found that one kva. transformer mounted wheels and rolled from one Multi- welder another will take care six eight because the high rate production. This kva. trans- former, Fig. will supply enough parallel spots. low-carbon steel were substituted for 18-8, this would cut about 20. Because the results shown the Multiwelders, the Douglas plant was allowed con- tinue using 18-8 stainless steel even 8—Shown here index spot welder for landing flap deflectors. The parts numbered are: spot welder panel; 2—index ma- chine frame; control place for welding. able kva. trans- former shows: Primary power leads; pads; 3—water cooling ducts: 4—magnetic switch; 5—electronic timer; 6—heat trols; 7—transform- er, volt, and re- lay for push button control. during the most critical shortage that material. Index Machine for Spot Welding Another Douglas development spotweld tooling index machine which spotwelds heavy channel and stiffener the inside tear drop shaped landing flap deflector. The deflector assemblies are from ft. length, have section welds and are only accessible through the open ends. The small section and great length make impossible insert electrode arm for conven- tional spot welding. Aerodynamic considerations require the outer skin depression-free; also, because the heavy gage the inside details, desirable use in. radius tip the inside elec- trodes and use flat skin-contoured tips the outer surface. Under these conditions the weld penetration the mating parts optimum. THE IRON AGE, August 4 The indexing machine which accom- plishes this difficult job, Fig. built around Sciaky kw. PMCO- spotwelder which been equipped with 150 amp. breaker and 650 amp. maximum current relay increase the output sufficiently offset shunting losses. The lower arm the spotweld ma- chine was modified boring and inserting air cylinder, Fig. for operation wedge mechanism raise and retract the lower electrode step with the lowering and retrac- tion the upper electrode. Another cylinder, Fig. 10, mounted the end the indexing werk table, also oper- ates wedge mechanism step with the movement the spotweld ma- chine electrodes expand and con- tract the internal electrode blocks meet and support the pressure the outer electrodes, and furnish series path between the two opposite weld joints. Water coolant cir- culated through the internal expand- ing electrode assembly. Cleco assembled are 1G. 9—The land. ing flap deflector was cut away show: and Upper retracting wedge, expanding electrode assembly; 4—replaceable inner electrode tip; Micarta pad; deflector skin; 7—channel fener; 8—lower elec- cylinder. placed the index table jig, the controls properly set, and spotwelds are made automatically in. inter- vals. the limit travel, the in- dexing mechanism reversed and spotwelds are placed in. intervals the return movement, halving the previous in. spacing. The next re- verse indexing movement, offset divide the previous spacing, closes the spot spacing in. centers, and the final run places them in. centers. Between the three in. center and the in. center runs, Internal electrode wedge operating showing: der case; 2—double acting air cylinder; 3—wedge actuating rod; 4—inner elec- trode support and coolant tubes; switches. ? IRON AGE, August 17, 1944 land. lower elec. internal sembly; inner eflector nel elec- the twelds inter- in- and ervals the re- set closes in. in. runs, Internal wedge Cylin- stuating micro- the current limit relay boosted about amp.; also the current boosted another amp. for the final run compensate for the increased shunting the spot spacing closes down. Time study shows that spotwelding this assembly takes only about one-fifth the time required flush rivet. Also, the outer surface the spotweld assembly aerodynamical- superior that the riveted as- sembly. Collet Dies Aline Flashwelds new development flashweld tooling which has not yet been tried pair collet type flash weld dies are par- show details. The numbered parts are: collet holder, upper half; 2—master collet holder, stationary half; 3—mas- ter collet, lower half; 4—master collet, shields; in- serts; hydraulic ment flash shields; portion holders which actuated hydrau- acting upon taper upper master collet, caus- ing segments clamp part concen- trically. production, but whieh shows con- siderable promise, collet flashweld die set. Flashwelds made conventional dies are only alined perfectly the mating parts are which never exists. Any difference diameter taken the top side the die, that with in. tolerance the top side the weld joint may misaline 0.020 in. While this misalinement would not great concern the case solid heavy walled stock, serious thin walled assemblies. in. wall thickness tubing the total dia- metric, wall thickness and eccentric- ity tolerances may reduce contact the top side little 0.010 in. under the most adverse conditions. This small contact area would not support the upset pressure, and the walls this side would push with- out forging. Such weld may pass proof load test, but fail service be- cause shock loading. The collet type dies, Fig. 11, alin- ing the parts concentrically instead the bottom side and give uniform contact the annular mating sur- faces; thus the width material not contact only half the total dia- metric difference. Since the mating uniform, the upset will uniform throughout the entire annular con- tact area and the resulting joint will strong either the mating parts. Tests experimental collet dies showed that much 0.030 in. differential tolerance could ab- sorbed with only 0.004 in. full indi- cator reading eccentricity the weld joint. The collet dies for production use are designed that the lower half the collet master rigidly at- tached the platens place the standard die masters and the upper half air applied after parts are in- serted. The collet segments are tight- ened means four small hydraulic cylinders mounted the master blocks. axial movement the col- lets takes place; instead the collets are fixed while the block moves. The collet segment assembly bored large inside diameter and acts insert master take all material sizes below bore means key and screw retained seg- ment block sets bored standard tubing and bar sizes. All current conducting parts are made Mallory No. alloy. Flexible conductors connect directly the moving collet tightening member insure good around the collet segment. Flash shields thin stainless steel are mounted both ends each collet assembly prevent flash from enter- ing between moving parts and thus