The Iron Age 1944-10-26: Vol 154 Iss 17

DEVENTER q BAUR General Editorial and Advertising Offices 100 Eost 42nd New York 17; Johnson, Market Research Hayes, Production Manager, Business Managers New York New. York 100 42nd St. 100 East 42nd Cleveland Chilton Bidg. Bidg. PEIRCE LEWIS WARREN RAYMOND KAY Angeles 2420 Ave. Owned and Published CHILTON COMPANY Executive Offices Chestnut and Sts. Philadetphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, Presiden? resses, HILDRETH Vice-President TERHUNE Vice-President BAUR Vice-President food WILLIAM BARBER, Treasurer JOHN BLAIR volves indexed the Industrial Arts index. lished every Thursday. Subscription North America, South America and Possessions, $8: Foreign, $15 Single Copy, cents. ° ° Vol. 154, No. IRON AGE Editorial Bombs and British Industry Technical Articles National Metal Congress: New A.S.M. Officers...... New A.W.S. Officers............ Basicity Open Hearth Slags (A.I.M. Core Sand for Magnesium Casting Progress Tin Smelting Control Acid Steel Fluidity Test Big Strides Made Welding Technique Support Arm for Portable Power Measuring and Designating Surface Finish Tube Bending With Precision Castings—Discussion Features News Front Assembly Line Washington West Coast Personals and Obituaries Fatigue Cracks Dear This Industrial Week News Industry News and Markets Buffalo Manpower Supply Eases Steel and Postwar Standardization Saves Bar Output Factory Employment Stays Near Peak Chemical Show Will Include Metals Industrial Pattern Shifted War Soldiers Build Bamboo Water McCarran Proposal Stirs New England Ire. Machine Tool Market Non-Ferrous Metals News and Prices Iron and Steel Scrap News and Prices Comparison Prices Week and Year Finished Iron and Steel, Steel Prices Warehouse, Semi-Finished, Tool Steel Prices Steel Pipe, Tubing, Wire Products, Prices Pig Iron and Coke Prices. Stainless Steel and Ferroalloy Prices Index Advertisers October 26, 1944 160 164-165 166 168 170-171 172-173 174 177-179 102 107 107 120 Member, Associated Business Papers 132 lon Whether you buy finished centers carbide tips for making your own, you can now obtain immediate ship- ments FIRTHITE from complete stocks. Finished FIRTHITE Centers 52—THE IRON AGE, October 26, 1944 are available with three tapers— Morse, Jarno, Brown and Sharpe. secure the maximum resistance wear, long life, specify FIRTHITE Grade for centers. Whe a | 4 4 | ° ° Bombs and British Industry (Cabled from London) Oct. 26, 1944 VAN DEVENTER and Editorial Director BAUR and General Manager completing interesting and intensive circuit covering industrial areas the London, Birmingham and Sheffield districts, position answer the question: much did bombing affect British industrial output?” DIX Manager, Reader Service Surprising may seem, the damage production, plants and equipment has been almost negligible. The same applies railroad transportation and also somewhat lesser measure docks and warehouses. Editorial Staff Associate Editers WINTERS ALBIN JOHN ANTHONY JACK HIGHT BARMASEL Editorial Assistants SCHIEN WILLIAMS CAMP MUNZER O'CONNOR MILLER LLOYD Pittsburgh 428 Bidg. Chicago DONALD EUGENE Washington National Press Bidg. Cleveland Guardian BRAMS 7310 Woodward OSGOOD MURDOCK San Francisco 1355 Morket St, Editorial Correspondents ROBERT Cincinnatt DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, KAY McCUNE ROY EDMONDS DOUGLAS IRON Whether caused design poor aim, the principal damage resulting from both the original blitz high explosives 1941-42 and the more recent and still occasional buzz bombing has been churches and houses the more congested areas. far in- dustrial operations are concerned, have yet find one instance plant even department having suspend for more than week and even this the exception. Some delays production undoubtedly occurred the days the “round the bombing because the insistence that workers take shelter during “immediate” but even this precau- tion became disregarded familiarity bred contempt. There are several theories attempting explain why more damage vital production was not done. One that the Luft- waffe chose cripple industry here terrorizing workers through the destruction their dwellings. Another that Hitler thought England was the bag” and wanted take over its industrial economy going concern and then use the islands springboard for the conquest America. Hitler, course, missed the boat. The same mistake not being made our Allied Air Forces which have concentrated industrial targets. However, the chief annoyance hot metal plants here has been the blackout. difficult ventilate steel works night with all windows covered. But has been much better than have both ventilation and plant ventilate. | | q { 4 j HIGHWAY GUARD MADE INLAND STEEL Each guard rail cold rolled form Many miles America’s highways are made extra safe hot rolled strip and flat bars rolled the Inland mills. These steel products are fabricated the Tuthill Spring Company, Chicago, into type highway guard that has great strength, cushions the shock im- pact, has high visibility, and easy erect and maintain. The guard rail made SAE 1045, gage, wide hot rolled strip cut ft. ft. in. lengths. These are multiple punched one end and multiple slotted the other end. Each 54—THE IRON AGE, October 26, 1944 Bars Fleor Plate Piling Plates Rail Reinforcing Bars INLAND STEEL COMPANY Dearborn St., Chicago Illinois Sales Offices: Detroit Kansas City New York St. Paul guard rail then cold formed through two-high stand give curvature 12-in. radius, resulting in. depth Each rail then cleaned power driven wire brushes made the contour the rail. Finally, each guard rail given coat paint. The brackets are formed from SAE 1095 spring steel bars, in. in. These brackets are heat treated for extra strength. The remarkable life saving record these highway guard rails added proof the uni- form high quality steel from Inland. Sheets Strip Structurals Tin Plate Track Accessories cred: acco: head time chem: duct: rate has $150 film ingo crea Front October 24, 1944 addition expanding its production facilities the addition least assembly plant and one new manufacturing plant, the Ford Motor Co. is. renovating sales structure. Efforts are being made stabilize the dealer organization, its average quality level and modernize for most efficient selling. new lower-priced car contemplated. That will carry the Ford nameplate indicates that successful will ultimately replace the standard series. This aggressive policy the part Ford suggests that its moribund aspects evident two three years ago have been transformed into new determination. Despite expected lower operating rate the postwar period, WPB manpower officials are predicting that per cent more steel workers will employed then than are working the industry now. This prediction based part upon the peacetime necessity for more workers finishing operations which have been abandoned wartime and part upon work week. Buffalo, favorite guinea pig for the poll takers, has received word that longer considered critical manpower area. Authorizations have been granted convert immediately civilian production. This the first break area that has been almost completely devoted war production for the past three The Germans claim that the Superfortress will used the Allies for blow this winter. Quoting data from the Japanese the Superfortress credited with bomb load about tons. Russians have fitted loud speakers aircraft, which cruise over German blast them with propaganda. The British first used this technique India control native populations. There much gossip Germany about the "V" weapons that authorities have take drastic steps protect military secrets. Several soldiers working launching platforms have been sentenced death, and others have been imprisoned. accumulates that actually will used the war lasts into the Spring. The Germans say will employed the air, land, and even from vessels sea. stated rocket shell very large size, although the size varie according use and method launching. Responsible British sources claim that large rocket shells are about completed, weighing tons and carrying 20-ton head. The British insist that this large rocket could arched over the through the stratosphere, and that such attempt will made the Germans time build new and very heavy launching platforms. projectile this size and range would easily the War's most astounding chemical and metallurgical feat. Metal working machinery disposed the RFC August brought over per cent cost. One week after the British government gives the ahead signal civilian duction, the Austin Co. expects have Automobile chasses coming off its line 400 week. Within three months, the production rate this company pected reach 1600 week. The postwar model will modified product. the rocket and heavy ammunition program the Ordnance Department has necessitated construction additions existing munitions plants involving $150,000,000. The new construction already more than one-third completed. spraying metal parts electrostatic field uneven distribution the eliminated, resulting improved finish uniformity and smoothness. Using higher potentials than electroplating, 100,000 volts, paint particles they enter the electrostatic field and are instantly attracted the part. being sprayed. Geneva has started its sixth open hearth this week which should increase its ingot production over the estimated break-even point. Greatest obstacle output the shortage male labor. KENT VAN HORN, president- elect the American Society for Metals, and research metallurgist, Aluminum Co. America. National Metal Congress yet, minions the metal working industry swarmed into Cleveland last week. They came away filled the gills with the technical roe the war years, better prepared face the peace. Approximately 40,000 people clicked the turnstiles the Cleveland Public Auditorium see displays occupying 167,000 sq. ft. floor space and run- ning the gamut industrial proc- esses. Attendance technical ses- sions the five participating societies was more selective, but topped pre- vious records. The American Society for Metals, American Welding So- ciety, American Institute Mining and Metallurgical Engineers held their traditional annual programs, joined this year the American In- dustrial Radium and X-Ray Society and the Society for Stress Analysis. the time the pub- lic address systems were packed away, 163 papers and lectures and round table discussion type meetings had been carried audiences. Next year’s Congress will held either De- troit, Chicago, Philadelphia, with final decision made later. Not appearing official programs, but nevertheless integral part the Congress were innumerable “bull sessions” affecting industrial progress URED the bait the biggest 56—THE IRON AGE, October 26, 1944 Metal Congress greater less degree, most them held overcrowded hotel rooms and lobbies. Traditional highlight the ASM meeting, the Edward deMille Camp- bell memorial lecture, presented this year Fitterer, dissected the topic, “Phase Equilibria the Acid Open Hearth Process.” Dr. Fitterer, head the department metallurgi- engineering, University Pitts- burgh, compared the melting and refining metals, which termed “still art,” heat treatment, which said had become science recent years. pointed out that “at the lower temperatures heat treat- ment fewer experimental difficulties are encountered than the high tem- peratures liquid steels. Many at- tempts apply the laws physical chemistry the acid openhearth steel processes have failed clarify the mysteries its operation.” “The usual physical chemical treat- ment acid openhearth refining reactions involves study the thermo-dynamic properties ments and compounds encountered the steel making reactions and the subsequent determination equilib- rium constants for the slag metal reactions,” declared. “This treat- ment has failed produce control methods clarify the operation the acid openhearth.” “Instead using thermodynamic methods, known equilibrium diagrams have been correlated illustrate the changes occurring acid openhearth slag during the refining period. This treatment resulted the explanation the differences between acid openhearth practice this coun- try and Europe. was shown that whereas some four seven hours are steel the acid process Europe, only hours are needed modern American practice. some plants the refining rate greater than one-half ton per min. “An explanation this improve- ment American practice possible consideration the equilibrium diagrams for the slag constituents. addition the mechanism oxidation the acid openhearth process easily understood the phase dia- grams are considered. new theory accounting part for the oxidation the steel during the refining period proposed.” Dr. Fitterer described control pro- cedure easily applied melt-shop personnel which translates into prac- tice the complicated background factors involving grams, fuel, dimensions the furnace and materials charged. See more com- plete abstract, page 62. National officers ASM elected the society’s annual meeting are headed Clevelander, Dr. Kent Van Horn, research Aluminum Co. America, who had been vice-president for the past year. Charles Herty, Jr., assistant vice-president, Bethlehem Steel Co., was elected vice-president. William Eisenman, secretary the society since its inception and largely respon- sible for its phenomenal growth, was reelected for 2-year term. New trustees, elected for 2-year terms, are Lewis Bergen, associate director metallurgy and research, Crucible Steel Co. America, and Robert Schlumpf, metallurgical engineer, Hughes Tool Co. Arthur Focke, research metallurgist, Diamond Chain Manufacturing Co., was appointed the board trustees serve out the remainder the unexpired term Dr. Herty trustee. Heavy emphasis the topic hardenability technical and group sessions gave added significance presentation the Albert Sauveur Achievement Award Walter Jominy, chief metallurgist, Dodge- Chicago division Chrysler Corp., developer the end quench test bear- ing his name. Robert Stanley, president International Nickel Co. Canada, Ltd., who inaugurated development and research department soon after rising the company’s presidency 1922 and aided nickel’s rise important place the alloy hierarchy, won the ASM Medal for the Advancement Research. Henry Marion Howe Medal for the best paper appear ASM “Trans- actions” was awarded jointly Earnshaw Cook, Fellows, and Flinn American Brake Shoe Co. Herbert French, ASM presi- dent 1942-43, received the past president’s Medal. All awards were < a © ° 7 f Previews Reconversion made the annual dinner the society. Panel meetings, dealing with indus- trial problems, and featuring off the record leaders the twenty fields covered, again were focal point interest. Attendance operating personnel well techni- cal men made audience discussion par- ticularly fruitful. throughout the country was drawn assertions made Victory Session speakers. Walter Tower, president, American Iron and Steel Institute, warned that the war created metal producing capacity the country might not fully utilized for many years following the peace. pointed out that following World War seven years was re- quired put steel production above the fifty million ton ingot war peak, and that the country prior 1940 never had seen any period consecu- tive years when needed average much 60,000,000 tons. With output today the ninety million ton level, said that “neither growth population nor increase per capita consumption seems promising enough bridge the wide gap between the old level average demand and pres- ent potential supply.” ‘ CHARLES HERTY, JR., vice- the American Society for Metals. Turning the problem drawing the war fangs aggressor nations, the AISI head said “the question access and use supplies metals stands the very front any con- those nations for ensuring peace.” declared that destruction the Ger- man steel industry would best only temporary measure. new industry, modern and efficient the last degree, could built, and Germany would ready prepare for its third World War,” empha- sized. his prepared paper, somewhat reduced actual presentation, Maj. Gen. Barnes, chief, research and development service, Office the Chief Ordnance, Army, plotted steps necessary for efficient postwar ordnance program. These in- cluded: (1) ordnance department made professional ordnance officers and maintenance and strength- ening arsenals and proving grounds for the solution technical problems; (2) large corps reserve ordnance technical officers constantly being ample funds for research and develop- ment order that contracts can placed with arsenals and industry for continual development weap- ons; and (4) complete cooperation all times with industries and all the great engineering societies and par- ticipation ordnance officers their activities. “The ordnance department has more than 1000 research and development orders placed with American indus- try for the development new and hitherto unknown weapons covering all ordnance fields,” the general said. “The rate production new weap- ons the moment approximately new items made ready for produc- tion per month.” Capt. Solberg, head, research and standards branch, shipbuilding division, Bureau Ships, Navy, announced that, extend the value high voltage radiography, the Navy now cooperating with the national defense research committee devel- oping and building million volt betatron machine. This unit will greatly reduce the time necessary radiograph heavy sections and will make possible sensitive radiography much heavier material than for- merly. ITH topics ranging from min- ing through processing fab- rication, the annual fall meeting the American Institute Mining and Metallurgical Engineers attracted substantial crowds and wide interest during four days program and business sessions Cleveland from Oct. 19. Two meetings were held mag- nesium, two creep nonferrous metals and alloys, one nonferrous production metallurgy, one steel; making, and another recent de- velopments analysis, along with two general sessions the Iron and Steel Division and one the Institute Metals Division. Inter- spersed were business and committee meetings, and the annual dinner, which the speaker was James Lincoln, president Lincoln Electric Co., Cleveland. American Welding Society, headquartered the Hotel Cleve- land elected new officers for the com- ing year. Weigel, the new presi- elected secretary the American So- ciety for Metals. THE IRON AGE, October 26, dent, the vice-president Combus- tion Engineering Co., New York. Mr. Weigel has been active the Welding Research Council, the Welding So- ciety, the American Society Me- chanical Engineers, and now the president the American Boiler Manufacturers Association and Industries. Isaac Harter, first vice-president AWS, the vice-president Bab- cock Wilcox Co., Barberton, Ohio. His activities have been basically around boiler construction and use, and was associated with the begin- nings the ASME Boiler Code and with the acceptance the Navy welding for pressure vessels. Dr. Wendell Hess, elected second vice-president, associate professor metallurgical engineering and head the- welding laboratory Rensse- laer Polytechnic Institute, Troy, addition many responsibilities connected with the war effort, dealing with the various phases welding the war production program, Dr. Hess has been active the AWS, the American Institute Electrical En- gineers, and the American Society for Metals. was also the co-recipient this year’s Lincoln Medal for paper, “Spot Welding SAE 1020, 1035, and 1045 Steels the 0.040-in. Thickness.” This year participated the establishment research pro- grams under the Office Production Research and Development WPB, and consultant welding prob- lems the American Bureau Shipping. Fraser, re-elected treasurer the American and Steel Institute, one the speakers the ASM Victory Sessions. the American Welding Society, director technical service mill products for International Nickel Co., New York. serves AWS chair- man the Nickel Alloys Committee, and has served member the executive committee and the Com- mittee Outline Work. His activ- ities for the International Nickel Co. include welding service work chromium iron alloys, and steel clad with these alloys. the annual meeting the American Welding Society, there were several papers presented that were winners the various awards. Dr. Wendell Hess, who prepared paper jointly with Lt. Herr- schaft, the Army, won the Lincoln Medal and also the $100 prize given the Resistance Welder Manu- facturers’ Association for the paper “Spot Welding SAE 1202, 1036, and 1045 Steels the 0.040-in. Thick- ness.” Duplicate awards were made these co-authors for their work. Lt. Herrschaft, graduate Rensse- laer, now the Army Air Forces, stationed Childress, Texas. Reginald Bland and Paul Sandorff were awarded Resistance Welder Manufacturers’ Association prize for their joint paper entitled “The Dynamic Properties Flash- Welded Tubing.” Both these men are senior research engineers with Lockheed Aircraft Corp. The Samuel Wylie Miller Memorial Medal and Certificate were awarded Llewellyn for his contributions the structural welding field. Mr. Llewellyn, now retired, former di- rector research for the United States Steel Corp. For outstanding service the development ordnance mate- rial, the Ordnance Distinguished Ser- vice Award was presented the American Welding Society Maj. ordnance. The presentation was made David Arnott, president the society, Col. Ritchie, from the office the chief ordnance. and vice-president Combustion Engi- neering Co., New York. ISAAC HAARTER, first vice-presi- dent, A.W.S., and vice-president Bab- cock Wilcox Co., Barberton, Ohio. WENDELL HESS, second vice- president, A.W.S., and co-author the paper that won the Lincoln Medal and the Resistance Welder Association prize. | a ate out Jol ser lin tio tio 58—THE IRON AGE, October 26, 1944 Examines Research Data powder added rough spoon mea- ETERMINATION the ba- sicity open hearth slags new and sufficiently accur- ate method which appears speedier than previous means was outlined the meeting paper Jolly, and Henry Wis- consin Steel Works. The paper, pre- sented Philbrook, was entitled Rapid Laboratory Method for Esti- mating Basicity Open Hearth The principle underlying this new method the well known fact that when burnt lime slaked lime shaken water dissolves least minor degree and produces alka- line reaction. Alkalinity can then measured titrating. the reac- tions are quite mild, they can de- termined immersion into the solu- tion some type electrode, such the vacuum tube “glass electrode,” which the very faint electromotive force measured through the high resistance glass membrane. The procedure outlined authors admittedly not perfect, but was pointed out that other method either. Error incidence was reported about the same other means. Final determination basicity, course, goes into the hands the laboratory technician rather than the furnace operator, but location the lab near the furnace could partial compensation for this disadvantage, such is. How- ever, the method has the favorable aspect eliminating human judg- ment factors favor mechani- cally reached conclusions, and also has the virtue being quickly installed and operable comparatively un- skilled hands. brief, the method testing starts with the spooning slag from the furnace and pouring into pan- cake mold, preferably tion for quick cooling. Naturally representative sample wanted, one without lumps undissolved con- stituents. After cooling lump crushed until all particles pass 40- mesh screen. Metallic iron re- moved and the powder thoroughly mixed. About 100 ml. water placed 250 ml. Erlenmeyer flask, which about 200 mg. slag surement. The flask shaken intermittently, and allowed stand for min. The meter checked for customary adjustments and temperature compensation and the temperature the slag suspen- After the glass electrode and sample cup are rinsed twice with the extract the reading taken. The lime- silica ratio the slag obtained reference correlated curve obtained from numerous measurements analyzed samples, taken under standard conditions slags less than one day old. was found that the weight —40 mesh powder suspended 100 ml. water was increased from 200 mg., the values increased, ° ° but beyond 200 mg. there was gain significance. Hence, measurement can rough long approxi- mates 200 mg. minimum. re- gards time standing, was deter- mined that virtually the full read- ing obtainable after about min. shaking, and that further standing did not vary the result any sig- nificant degree. The simple expedi- ent stoppering the flask during the standing period eliminated any pos- sible absorption carbon dioxide from the air. Ordinary distilled water can used for the work. Increasing temperature the solution appeared have the effect deg. Recommendation made, therefore, that readings held rather Finally the technicians established that there was consistent drift slags pulverized intermittently days after pouring. This was notable, for obviously permits the use the process for study sev- eral days after the heats have been produced. Magnesium Casting Quality Examined quality magnesium castings becomes constantly more im- portant, problems microshrinkage and grain size have been under in- creased study. These twin headaches for metallurgists, manufacturers were discussed paper Oscar Blohm, chief metal- lurgist, and Havens, the metallurgical staff, Hills-McCanna Co., Chicago, dealing with that Affect the Physical Properties Magnesium Sand Castings” ASTM and ASTM Alloys. Fine grain size, said Blohm read- ing the paper, does not necessarily result from recommended superheat- ing. standard schedule does not produce fine grain metal consistently. Because impossible judge be- forehand what superheating each crucible needs produce certain grain size, foundries are obliged adopt practice and hope for the best. Fur- ther, grain size any one casting varies, depending section thick- ness. stated that pouring temperatures castings must established trial order reduce amount and degree. Some must poured always low temperature, and these will nearly always have coarser grain than others poured high temperature, regardless superheating prior pouring. was opined that sound casting with somewhat coarse grain preferable fine grain casting containing appreciable microshrink- age. routine test procedure followed Hills-McCanna, including physical testing bars from every heat, X-ray examination and daily grain THE IRON AGE, October 26, 1 4 4 q q q 4 size determinations all production material, chemical analysis every heat, and fracture tests for visual ex- amination. Whenever any substand- ard condition revealed, further metallographic investigation takes place, including compound, porosity and precipitate rating, well grain size count and X-ray correla- tion porosity rating. Observations derived from these test bar failures and related data have led six tentative conclusions, follows: 1—Grain sizes 0.02 in. can meet present physical requirements set forth ASTM, AMS, and covering the sand cast magnesium alloy cast- ings. 2—Microshrinkage, porosity, has more deleterious effect phy- sical properties than has coarse grain the limits mentioned above. The distribution microporosity test bar most critical factor determining bar failures. General distribution more effective for given porosity rating cause bar failure. 4—The frequency bar failure grain size range 0.02-0.04 in. becomes prohibitive (63.6 per cent) while due porosity be- comes fatal rating number 5—If any failure perform ser- vice occurs, examination made possibilities other than the two factors discussed above. While there suggestion any specific cause, one possibility which must considered the design the part. 6—It well remember that the optimum physical properties and service can obtained with com- bination fine grain and minimum porosity. These are attainable goals when close cooperation between designer, foundry and ultimate con- sumer prevails. Core Sand Mixtures for Magnesium ETAILED discussion experi- ments with core-sand mixtures for magnesium castings the Lock- land, Ohio, plant Wright nautical Corp. were described Jay Myers, metallurgist that plant, his paper, “Oxidation Inhibitors Core Sand Mixtures for Magnesium Castings.” For this work, typical heavily bonded blow machine core sand mix- ture was used, compounded fol- lows: 1000 round grained Ottawa- type silica sand (G.F.N. 62-65); Ib. cereal binder: pt. low-baking temperature core oil; and 1.5 per cent moisture. small mold pattern was constructed provide necessary cores for hollow, truncated conical cast- ing, in. high, in. diameter base and in. diameter top, enveloping pencil core in. diameter. Pour- ing was vertical, the gate entering the small section with the risers taken off the large section. Facing sand the mold was mulled batches, mixing time being min. dry, min. with water and min. with oil. Cores were hand rammed and baked labora- tory gas fired oven for hr. 350 deg. Tensile briquettes accom- panied each mold the oven. standard method was worked out pour the castings from production superheating pots, pouring being temperature range between 1350 and deg. Cooled castings were knocked out and sandblasted; sprues and risers were cut off bandsaws, 60—THE IRON AGE, October 26, 1944 after which the castings were sawed lengthwise. Half each casting was cleaned abrasive wheel, then X-rayed, while the other half was fractured. Twenty sand mixtures were made, each which contained different proportion inhibitor added the basic formula. The conclusion these experiments was that combination sulphur and boric acid was better than the use either singly. Experimental production runs have been made lowering total percentage these agents one per cent, with excellent The first mixture, tried without in- hibitor, resulted casting with heavy burned skin. Burned sand clung the casting knockout. Numerous pits were revealed the surface, showed internal burning. graphic examination revealed heavy interstitial burning. ° When 0.5 per cent sulphur weight the sand was added, similar properties were manifested the casting, but reduced measure, in- dicating still inadequate protection. sulphur was added increasing amounts was found that 2.5 per cent addition brought definite im- provement, reducing severe burning minimum, but leaving the surface covered with charred binder. per cent level sul- phur addition, tensile strength and green compression the sand mix- ture reduced, and the casting was not improved. Boric acid was then tried. With 0.5 per cent addition, the casting was satisfactory its predecessors. broke free from the mold knockout, showed only slight surface discolora- tion, pits surface, serious in- ternal burning, and reduced porosity. When increasing amounts boric acid were added, tensile strength the baked sand mixture dropped. while green compression became slightly greater. Castings changed. satisfactory casting was produced with 2.5 per cent boric acid added, but gas emanated from the risers pouring. With per cent the casting was unsatisfactory. The next series attempts used both sulphur and boric acid. satis- factory result was achieved with 0.5 per cent each ingredient the sand; and with higher amounts similarly satisfactory results came about, except where 2.5 per cent each agent was used. inhibitor percentages increased, however, the physical properties the sand dropped far below optimum work- ability. Using 0.5 per cent ammonium silicofluorite, the casting was well protected, but green compression and tensile strength the sand was low- ered. Diethylene glycol, 0.5 per cent added, gave some protection the casting, leading the possibility that combining with low baking tem- perature core oil might prove profit- able. ° Processing Beryllium history and processing beryllium was treated sur- vey type paper, “Beryllium,” pre- sented the meeting Donald Liddell, New York consultant. His discussion processes reducing confirm the statement quoted from Dr. C...B. Sawyer, that “the world’s No. metallurgical headache.” “Metallurgy this element,” the speaker stated, “is perplexing prob- lem because the metal has high fusion point and high vapor pres- sure temperature not much above the fusion point; the pure metal ex- ceedingly light and has tendency float slags and fused electro- lytes; the halides are all highly de- liquescent and after they have ab- sorbed sim hydroli lium tent other dency Mod author berylli 1915. lates beryll The the tail. and The The crust hot the alum nate adde cipit drie mon mor liun sorbed water from the air they cannot reconverted anhydrous salt simple heating, all the halides hydrolize readily; and when beryl- lium hydroxide precipitated has tendency occlude and adsorb other salts, and there also ten- dency form basic and oxysalts.” Modern processes described the author are largely based bringing beryllium into solution alkaline fluoberyllate, this method having been initiated Copaux his French patent, No. 476475, issued 1915. Alternately the beryllium dissolved beryllium sulphate such processes spring from the fact that alkaline lates are soluble water, while beryllium fluoride not. The Perosa process for the recovery the metal was described fair de- tail. Beryl heated, then crushed and ground all passes 100 mesh screen. then mixed with acid sodium fluoride atomic proportion 1:4, and the mixture briquetted. The beryllium converted sodium fluoberyllate when the briquettes are sintered from 650 800 deg. The sintered briquettes are then and ground and leached with hot water. Sodium hydroxide added, making the mixture exactly neutral and puri- fying from iron, manganese and alumina; and potassium permanga- nate added. The iron-manganese- alumina precipitate filtered off, and excess sodium hydroxide added. Beryllium hydroxide pre- cipitated, filtered off, washed and dried. After drying the material ground paint mill with acid am- monium fluoride, which converts the hydroxide ammonium-beryllium fluoride. This then briquetted and heated sufficiently drive off the am- monium fluoride, leaving pure beryl- lium fluoride behind, which then reduced with magnesium mag- nesium alloy.in the presence some the metal desired for master alloy. this process, others, the high cost fluorine necessitates its recovery out the solution from which the beryllium hydroxide pre- cipitated, and out the slag the final reduction well. Several electric furnace processes for reduction beryllium have been developed and patented the United States recent years. Burgess produced beryllium carbide beryl- lium silicide, distilling off beryllium chloride. reduction, tetraberyl- lium trisilicide was formed, and formation ferrosilicon the fur- nace worked means con- centrating scoria (U. pat- ent No. 1905340; issued Production ferrosilicon was also Kjillgren Patent No, 2092621; issued 1937). Using pyrite sul- phur source, Lowenstein produced beryllium sulphide furnace (U. Patent No. 1777267; issued 1930). sulphide was also produced Gardner sulphurizing with disulphide the presence excess carbon 1800 2000 deg. (U. Patent No. 2166659; issued 1930). Armstrong reduced with ° ° carbon temperature high enough volatize the silicon, then leached with hydrogen sulphide (U. Patent No. 2273168; issued 1943). Beryl, which its purest contains about per cent beryllium oxide, the only beryllium mineral war- ranting commercial attention. found Brazil, Argentina, India, Canada and Portugal. The richest mineral this respect, however, beryllium orthosilicate, which contains 45.55 per cent beryllium oxide but which rather rare. ° Smelting Complex Tin Ores creased great deal commer- cial importance since the Japanese invasion the Malay States and the Dutch East Indies have forced reli- ance Bolivian and Mexican mines provide the United States with its tin supply, and complications Bolivian ore rindi Ball digesters liquors Waste ary Disposal plant Reverberatory furnaces Low-grade concentrates roasting such ores were described paper Mantell, New York consultant, dealing with “Recent Progress Tin Smelting and Metal- lurgy.” Ore dressing processes have had developed for stannite, cylindrite, (CONTINUED PAGE 118) Bolivian concentrates Roasting and Petroleum leaching plant coke acid Separate treatment for production common tin HOWN the flowsheet from ore tin bullion followed the necessarily complicated process installed the Longhorn, Tex., smelter, described the THE IRON AGE, October 26, y | e \- r > | | t | | Exhaust Dressing Ball oyster shell Crushed semi-anthracite coal precipitator slag kettles metal . q Saiger bins Crude furnaces GEORGE FITTERER Nineteenth Campbell Lecturer ODAY, the acid furnace an- nually responsible for from two three million tons large forgings and castings which are re- quired Government and industry. Most the steels produced are medium-carbon and low-alloy types, whereas many semi-steels high- carbon irons are also made. Large caliber guns, marine crankshafts and connecting rods, shafts for steam tur- bines, locomotive parts, roll housings and rolls are examples its products. Great strides have been made this country the past several years reduce the refining time the acid hearth exceptionally low figure. Many heats are produced with more than 2-hr. period from the time the heat completely melted until tapped. losses nickel molydenum are encountered. These alloying elements are retained from remelted scrap and may charged added any time during the heat. Chromium losses are nominal and considerable amounts chromium may retained from the remelted scrap. These factors should placed the credit side the ledger for the acid open-hearth and are some the reasons for its continued use. the debit side are usually placed (1936). 189. (1923). K.W.I. 14, No. 13, 181. (1932). 62—THE IRON AGE, October 26, 1944 Control the Acid Open FITTERER Head Department Metallurgical Engineering, University Pittsburgh Abstract 1944 Campbell Memorial Lecture. the facts that, first, low phosphorus and sulphur charge must used; and, second, generally considered undesirable use light scrap because the high formation iron oxide and the subsequent erosion the acid silica lining the furnace. This short refining period par- tially accomplished using low percentage pig iron the charge, and the low sulphur and phosphorus requirements the pig iron are mini- mized somewhat this manner. The scrap, however, must still low these elements. The use light scrap the acid open-hearth quite com- mon today, although heavy and medi- scrap are preferred. The statement has been made many previous investigators that the acid open-hearth operates closer equilibrium than any other steel mak- ing process. Unfortunately, this state- ment has never been clarified qualifying clause, indicating cally which phase the process equilibrium. One objective this paper seek justification for this conclusion and specify which equilibrium, any, the acid open- hearth approaches. critical survey the available physical chemical data has been made the author order determine their usefulness the acid open- hearth industry. This paper deals specifically with search for the equi- librium which the acid open-hearth reputedly approaches many pre- vious investigators have stated. the acid open-hearth there are both heterogeneous and homogeneous reactions considered since there are four phases involved: the solid (or the SiO.) lining, the gas, the slag, and the metal bath. Strictly speak- ing, practically all the reactions occurring the process are hetero- geneous nature are dependent upon other heterogeneous actions. Most the previous investigators have been concerned with the compet- ing reactions carbon, manganese and silicon with iron oxide the metal bath. Practically all these studies have involved attempts ex- plain the sources iron oxide for purposes these reactions. gen- erally assumed that the oxygen fur- nished the metal the slag and that the iron oxide distributed be- tween the slag and metal accord- ance with distribution ratio. How- ever, where the previous investigators attempted explain the activity the state which the FeO the slag, they encountered maize con- tradictory data and found neces- sary resort arbitrary assump- tion this regard. For example, many excellent inves- tigations such those Schenck,’ centered the assumptions that iron oxide existed the liquid slag definite chemical compound ferrous silicate. This was dissolved according these authors and dis- sociated some extent that the slag was essentially composed FeO, “free” SiO: and some un- decomposed silicate. The “free” FeO turn diffused into the metal bath where reacted with carbon and the other metalloids. This procedure would highly use- ful were not necessary assume value for the dissociation constant the silicate. There seems ready and re- liable experimental method for the varification the assumed dissocia- tion constants and none this in- formation promises develop prac- tical control methods the very near future. Inasmuch this the aim the present investigation all the A 4 prev rese othe stuc hea: dyn hyp wit tail tice ine phe cre the pre tio cel Hearth Means Slag Fluidity Test previous data concerning the physical chemistry the acid process will reserved for future study. Instead, other methods for control have been sought and this led the author study heterogeneous equilibria phase diagrams. From study phase diagrams would appear that the acid open- hearth tends approach state dynamic equilibrium, although unlikely that any heats reach that hypothetical state. However, ap- parent now, that the acid slag contin- uously approaches saturated state with respect content. The rea- son that saturation difficult at- tain that usual American prac- tice, the temperature constantly increasing throughout the heat. With increased temperature two phenomena may occur. First, since in- creased temperature demands higher SiO. content the slag for satura- tion, some may obsorbed from the furnace walls particularly that portion the slag which the proximity the banks. The slag the center the fur- nace, however, may approach satura- tion converse manner. Study will reveal that whereas increased per- centage SiO. required for the saturation the slag relatively higher temperatures, this may ac- complished not only increase well. other words, less FeO re- quired relatively higher tempera- tures saturate the silica and hence the temperature increases be- comes free react with the metal- loids the bath. Apparently both increase SiO, the slag near the banks and “precipitation” FeO content the center the furnace occur simul- taneously most heats. The release for reaction with the metal- loids undoubtedly accounts for part the oxidation. However, study the oxygen balance various heats indicates that this procedure may represent about per cent total oxidation. this reason, oxygen balance has been made recent heat. total 0.49 carbon, 0.11 manganese and 0.04 silicon were removed during the refining period. the basis ‘the 81,620 lb. charged, this represents total 2675 lb. FeO required for the removal the metalloids. FeO “precipitated” from the slag was calculated 449 lb.; FeO from ore additions, 304 and available FeO “freed” limestone, 576 This leaves the per cent FeO still unac- counted for 1346 lb. This would indicate that approximately one-half the FeO needed eliminate the metalloids must have originated from some other source than the slag slag additions. This led more thorough study the possibilities oxidation from the gas. The common opinion concerning the mechanics oxygen transfer through the acid open-hearth slag the metals that the acts carrier agent according the reactions. the gas-slag interface and then slag-metal interface. During the boil the convection cur- rents cause the which formed the top the slag transferred the metal surface where re- duced FeO. This feasible theory but requires extremely rapid and continuous transfer very small quantity present during the active part this heat, then only 14.1 lb. must carry the oxygen from the gas the metal according the above reactions. Because 1346 lb. were needed and un- accounted for, essentially round trips for the were required dur- ing the refining period. other words, there would necessarily replacement all the about once every minute and half this basis. This not inconceivable, but does not satisfactorily explain the en- tire mechanism which oxygen transferred from the gas the metal phase. the beginning this lecture, was stated that the ultimate goal any physical chemical study steel making processes should the de- velopment control methods which can used the melt-shop person- nel. possible control method for the acid open-hearth was the objective this investigation. has been pointed out herein that the temperature acid open- hearth heat increases, the tent the slag increases proportion- ally, whereas its FeO content de- creases. was also shown that the MnO content the slags remained essen- tially constant throughout American heats. Hence, would appear that any quick test which would determine the SiO, content the slag would also permit the estimation the tempera- ture the slag well its FeO content, provided course, that the usual MnO value the slag for the given practice known. This conclusion logical because the location any point ternary diagram may found the percen- tages any two the three constitu- ents are known. this case the content the slag may de- termined quickly some means and the MnO content set charging practice, then the FeO content the slag well its approximate tem- perature may determined. This becomes apparent after reconsidera- tion the ternary diagrams. Here was shown that the composition the slag with respect and FeO contents was determined the tem- perature and its MnO content. The question now arises what quick and simple test may taken the melt-shop personnel and used determine the course the heat this basis. The method deter- mination slag fluidity similar that described Herty for basic open-hearth slag was.selected for the purpose quick determination content. The test mold used this work had %-in. bore instead in. sug- gested Herty. The former diam- eter has been found more uni- versally useful for the acid open hearth. sketch the mold being used the Acid Open Hearth Re- search Association shown herein. Juppenlatz and Kramerov have shown that the fluidity acid elec- tric acid open-hearth slags function their contents. This relation has been confirmed the work some the author’s asso- ciates and some recent data are shown. this figure may seen that THE IRON AGE, October 26, — e- X~- r- n- s- 7 2 4 the flow fluidity test quite sensi- tive changes SiO. content acid slags. One inch flow equiv- alent minus one per cent ‘The slags having long “run” above in.) are very early slags. the heats progress’ the content increases and the fluidity decreases proportionally. Usu- ally tapping slags run from in. in. this mold. Some plants oper- ate towards 6-in. run tap and others towards 9-in. run, depending somewhat the product. The points this figure represent tests made two heats from different plants—one casting and the other ingot shop. Hundreds such tests have been taken the author’s asso- ciates and known that this rela- tion reliable. The significance this test fur- ther clarified the relation fluidity content kept mind while studying the diagram shown herein. heat charged give per cent MnO the slag would tend fol- low the per cent curve this fig- ure the temperature increases. The fluidity test may taken any time during the heat and the may estimated from the fluidity curve. The content may then determined from this figure since the SiO, and MnO contents are now known. The minimum temperature may also determined. for example the fluidity reading were in. for given slag then the content would approximately per cent (according the fluidity With per cent and per cent MnO the ratio 3.6 according fig- MnO ure. Hence, the per cent. lime has been added the heat, this represents essentially per cent FeO. the other hand, limestone used and the usual slag contains per cent CaO then there approximately cent FeO present. addition, may seen that the minimum temperature this particular slag sample was about 2940 deg. F., according the diagram. combination the fluidity curve and the ternary diagram may then used guide the plant person- nel. The fluidity values may trans- lated into and FeO contents the slag well give estimate the temperature, providing the usual MnO content the slag known for the practice under con- sideration. Fluidity readings taken too soon 64—THE IRON AGE, October 26, 1944 after limestone iron ore addi- tion should avoided, because the fluidity will abnormally high. Some min. should al- lowed after such additions order obtain reliable fluidity value. Silica content the slag, per cent Relation silica content slag fluidity the acid open hearth. per cent ~<— per cent »weight per cent Section system showing composition slags from acid open-hearth heats. inte Viscosimeter tor use with acid cha ods ves Big Strides Made Welding Techniques few the highlights the more papers presented the 25th annual meeting the American Welding Society, held Cleveland. Research the weldability metals continues sev- eral fronts. New methods and new materials have been developed meet wartime needs. Welding Shipbuilding ELDING large ships here stay and the perfection the art will the aim all interested the marine field and welding generally, according Rear Admiral Howard Vickery, vice- chairman the Maritime Com- mission, who spoke the opening ses- sion the American Welding Society. The entire course the shipbuilding program was built around the all- welded ship and has proved distinct success, said, since has