The Iron Age 1945-01-18: Vol 155 Iss 3

VAN DEVENTER President and Editorial Director BAUR Vice-President General Manager ° ° ° Editorial and Advertising Offices 100 East 42nd St., New York ° ° ° Johnson, Manager Reader Service and Market Research ° ° 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 Bidg. Park Philadelphia Chicago Chilton Bidg. 1134 Otis PEIRCE LEWIS WARREN Hartford Conn. Detroit 7310 Woodward Ave. Box RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY (Incorporated) Executive Offices Chestnut and 5éth Sts. Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH Vice-President GEORGE GRIFFITHS Vice-President 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 Circulation Member, Associated Business Papers ° Indexed the Industrial Arts Index. Pub- lished every Thursday. Subscription North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents. ° ° ° ° ° ° Copyright 1945, Chilton Company Vol. 155, No. The IRON AGE January 18, 1945 News and Markets Steel Price Rise Announced Delivery Delays Finished Steel Scrap Institute Australian Production Mineral Production Summary Machine Tool Market Developments Non-Ferrous Metals News and Prices. Iron and Steel Scrap News and Comparison Prices Week and Year. Finished Iron and Steel, Steel Prices Warehouse, Semi-Finished, Tool Steel Prices Steel Pipe, Tubing, Wire Products, Pig Iron and Coke Stainless Steel and Ferroalloy Prices Index Advertisers Editorial ° Technical Articles Coated Abrasives for Production Surface Powder Brazing for Tipping Metlbond Adhesives for Magnesium Fires Controlled With Short Cycle Malleabilization White Cast ° ° Features ° ° ° 148-149 150-151 152 153 160-161 | G | | ind a uts ° nes can drawn better (THE STANDARD CARBIDE) Many leading manufacturers are using FIRTHALOY Dies draw and form wide variety shapes and sizes. Such forward-looking manufacturers have found that FIRTHALOY’S resistance pressure and abrasion makes possible these economies: (1) Long production runs—often from 100% 1000% increase; (2) Reduced number passes; (3) Better finish, and uniformity size; (4) Lowered operating costs. Quotations Request. Please furnish following informatior when requesting quotation: {a) Type and metal drawn: 46—THE IRON AGE, January 18, 1945 = 4 a = & : — — i i 2 q ESTABLISHED 18, DEVENTER and BAUR Vice-President and General Editorial WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Editorial Assistants DAVIS News and Technical LLOYD Pittsburgh Park Bidg. POST Chicago 1134 DONALD BROWNE EUGENE HARDY Washington National Press Bidg. LLOYD Cleveland Guardian BRAMS Detroit Woodward OSGOOD MURDOCK San Francisco 1355 Market ROBERT Cincinnati DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, KAY Los Angeles Birmingham ROY JAMES DOUGLAS Seattle You Know What Work YOU know the meaning work? seems strange question ask people who read this publication, which devoted entirely that subject! thought knew what meant, having lived with for some forty years. But have become disillusioned looking the dictionary. Work, according that supreme court syllables, has more than fifty meanings. They range from “to create” “causing liquors ferment.” Evidently the seeker after work, confines himself the dic- tionary, has plenty choice. found also that over the centuries, starting with Adam, man’s attitude toward work has undergone considerable change. The original conception it, following the expulsion from the laborless Garden Eden, was punishment for sin. Our fathers and grandfathers regarded duty and privilege earned the willing and conscientious expenditure effort. Many this generation regarded right, leading meal ticket and one that conveys obliga- tions upon the recipient. Sometimes wonder where work stops and play begins, especially after watching hockey game. saw one the other night between the teams two noted universities. could not help thinking that workers industry had undergo the punishment banging their heads barriers, taking dangerous falls every few minutes and having their shins cracked repeatedly, there would certainly strike, pronto! Perhaps the answer that the difference between work and play that the latter work that does not have done and that not paid for. Now that are talking about maintaining sixty million jobs this country, perhaps should know more about not only what work but what does. From this angle like the one the fifty meanings the dictionary which says “to create.” That does not mean just create employment. make job just for the sake making without regard the values produces social liability and not asset. Jobs, have social value, whether made order ready made, should such produce economic values. Private industry needs urging this point, because its jobs must necessity self-liquidating keep the employer out liquidation. But government made jobs are not under that compulsion since the burden falls the taxpayer. Government can best create jobs with social value helping private industry make them, rather than attempting compete with it, red ink employer. | | q | 4 ) MUNZER O'CONNOR MILLER HANSEN For Finer Steel Consult Inland when plans are started for parts products which must have the strength, utility, and beauty that can come only from steel sheets and strip. Inland was among the first install modern continuous mills. Its engineers and metallurgists have contributed many notable advancements sheet and strip Sheets Strip Tin Plate Bars Plates Floor Plate Structurals Piling Rails Track Accessories Reinforcing Bars INLAND STEEL COMPANY Sales Offices: Cincinnati Detroit Kansas City One the Inland cold reduction mills, which strip precise thickness and produces lustrous afte: production methods and quality control —resulting unsurpassed uniformity, workability, and finish. Inland experts are ready help you select the right steel for finer products and economical fabrication—whether the products are for wartime use, for the markets that will follow Victory. News 16, 1945 Recent Russian technical data disclose for the first time producing ferrovanadium from asphalt derived from Ural crudes. Vanadium runs high per cent the ash. California and Oklahoma crudes contain considerable percentages vanadium, least one company may experiment with the same process. Spalling metal the outer railroad rail curves has been experienced greater degree some the heavy traffic Eastern railroads. overcome one the rail makers has rolled per cent chromium rail which air and has much higher Brinell hardness than standard rail. And: This rail now undergoing field tests. Cancelling draft deferments one out three men the group meded industry will cause per cent loss war production, WPB study Plans are being formulated lessen this withdrawal that the new mon schedules can met. Cadmium increasingly tight supply, with 1945 requirements per cent production down per cent from last year. Government stockpiles cadmium mso were reduced about one-third during 1944. The RFC, through the Metals Reserve Co., has spent about $2,000,000,000 for purchase strategic and critical minerals. Because great many the mterials have been bought more than ceiling prices, losses through sales OPA levels have been $26,500,000. Engineers has placed order for 4000 aluminum with Shipbuilding Corp. Portland. Maritime Commission has authorized this divert 3000 workers for this new enterprise. believed many the Pacific Coast that manpower problems there would very serious workers were honestly and efficiently utilized, there little less poker playing some private managements, and less fumbling public agencies responsible for the freezing, unfreezing, allocation, re- which and manipulation manpower. lawsuit the Government vs. Cold Metal Process Co., Youngstown, basic covering the cold rolling steel, closed last Thursday Cleveland five weeks hearings. interesting angle these hearings was that for the first time X-ray dif- patterns were accepted legal evidence disprove Cold Metal's claim Steckel rolling random grain orientation rolled steel obtained. Best opinion Cleveland that Cold Metal has lost the case. Disputing much recent publicity, the General Motors director new devices, last week that there would not swing from SAE steel specifications the AMS specifications. Furthermore: expected early revision SAE specifications many accommodate the growing acceptance leaner alloys, but expected steel disappear early the postwar period favor the usual old specifications which prevailed the days freer ferroalloys. strength bonding agent for metals and non-metals that can cured low pressure inexpensive jigs has been developed Consolidated Vultee. agent combines two adhesives, one having synthetic rubber base and the other base. Drill breakage has been reduced new fixture, torque coupling which the drill predetermined point then reassumes the load the driving torque returns normal. incipient brewing between the AFL Detroit Building Trades Council the CIO Maintenance and Powerhouse Council. The AFL has refused work plant unless they can obtain agreement that they will not have with any CIO members. far two minor strikes have resulted. More are j > | J q | 4 | 4 3 | 4 > 3 id ‘ | 3 ‘ i 1G. Photo- micrograph sili- con carbide grains showing typical frac- ture into long sharp crystals limiting its usefulness but ideal for soft metals. Aluminum oxide grains, the other hand, have massive appearance. Both are made high temperatures the, electric furnace. Increased accuracy and greater are being attained with coated abrasive belts placed jobs that impose surface finish requirement with stock removal low production cost basis. stimulus for the develop- ment many diverse types machines for use with the abrasive belt was felt the beginning the war production pro- the aircraft fac- tories—when was necessary utilize the productivity unskilled labor. being recognized that eonverting for postwar production, the problem giving jobs consider- able numbers unskilled operators will again encountered. Fabrica- tors are including their plant con- version studies the types machines described this article representa- tive the prevailing stage refine- Glue Covered ment attained the belt surfacing technique. Although the capabilities these machines and resulting low produc- tion costs have aroused much interest, any picture the belt technique reconversion program will out balance unless the part that has been and being contributed the coated abrasives manufacturers discerned and evaluated. The high uniformity metal finishing with coated abrasive belts attests the success policy product standardization carried out the manufacturers. Rates stock removal and resultant quality sur- face finish for any grit number have ALBIN ro) ° passed beyond the trial and error stage, far the user concerned. trip through the plant coated abrasives manufacturer very con- the critical matter abrasive grain uniformity for any specific grit number. [The grit num- ber the number openings per linear inch the screen used select abrasive grains certain size.] The laboratory staff needs keep constant check the grain sizes order that the proportions coarse and fines kept within permissible limits estab- lished the trade. increasing slightly the proportion coarse grains for given grit number possible gain faster cutting, but the quality surface finish left un- certain. The modern scientific methods grading the abrasive grains re- sponsible for the production belts giving faster cutting, smoother fin- ishes over wide-range grits and reduction the percentage ma- terial rejected because wild scratches ®ther surfacing imper- fections. Machine tool designers realized that the coated abrasive belt they had cutting tool consisting millions the Electro coating meth- for attaching abra- sive grains the back- ing. Grains compelled follow lines force become anchored the bond with their long axes right angles the backing and evenly spaced. ° ° ° IRON AGE, January 18, 1945 Force Coated Abrasives . Fig belt ren fro cut the abi cutting edges traveling rapidly over the entire surface the the same speed, thereby imparting uni- form finish. Very few cutting tools are hard tough aluminum oxide grains used belts for surfac- ing steel, sharp silicon car- bide grains which are more satisfac- tory for the soft metals, plastics, glass, etc. Another characteristic these grains that they refracture the course being dulled usage, presenting new sharp cutting points, Fig. Each grain abrasive the belt performs like cutter tool, each removes chips that resemble the chips from lathe, shaper tool milling cutter—as illustrated the enlarge- ment, Fig. Another factor which contributes the efficiency the belt the greater cutting area over that other abrasive methods. The belts average length ft. for most the equip- ment described this article. Belts run cooler, hence work hardening the part under control. They can handle any type outside grinding and finishing from deburring grind- ing down welds. The cutting efficiency the grit further increased the grain and material being worked are kept cool water other coolants. One the advantages the belt over solid types grinding mediums that flexible enough con- form irregularities the surface being ground, though special devices are usually required for such opera- tions. Coated abrasives manufactur- ers make careful check tests the backing insure its possession uniform firmness prevent the abrasive from receding into the back- ing. The backing must also suffi- ciently tough withstand the strain continuous high speed operation and heavy grinding. The use waterproof adhesives has greatly increased the applications coated abrasives the metal work- ing field. The Electro coating method applying the grains the backing contrast the older gravity 1G. Photo- micrograph steel shavings cut aluminum oxide indi- cating how the abra- sive grains actually cut like tiny chisels rather than rub the material away. method has resulted abrasive belt surface exceptional evenness, permitting tolerances held the region 0.0005 in. with certain ma- chines. See Fig. Surfacing Factors can inferred from the fore- going that many variables are en- countered the average surfacing job. The first factors consid- ered are the kind and the condition material ground, the amount stock removed and the fine- ness finish required. Next, must determined what method the operation will performed and final- with what type abrasive belts, grit numbers and what speeds. Rather than see war plants and other fabricators assume the burden experimenting, often the cost much time and expense, the coated abrasives manufacturers have taken active part the solution their surfacing problems. Not only have the abrasives manufacturers advised the best methods and means for handling particular products, but they have endeavored cooperate more generally with fabricators through comprehensive plant surveys under- taken engineers field representa- tives experienced coated abrasives applications. such surveys careful study made installation and pro- duction costs before recommending changeover from existing surfacing methods coated abrasives. help expedite plant surveys and solve product surfacing problems pro- posed fabricators, Behr-Manning Corp., Division Norton Co., Troy, Y., has coated abrasives applications “clinic.” Practically all this the machines described article are found Behr-Manning’s clinic and are used for running tests and experiments connection with customers’ surfacing projects. One its departments devoted ap- plications coated abrasive special- ties “gadgets,” such slotted disks, bands, points, and pencils.* *See the article entitled “Coated Abrasive Gadgets Speed Finishing Oper- ruary 25, 1943, 48. Surfacing with coated abrasive belts can better appraised the machines are separated according three functional groups. the first group are the machines which depend upon contact wheel for efficient stock removal and finishing. the second group are machines which have been designed for finishing parts having uneven surfaces recesses, ad- vantage being taken the flexibility Cutaway section leather compress wheel showing segmented construction. The leather wheel ad- visable for hard cutting work; canvas wheel for moderate cutting and finer finishes. Courtesy—Divine Brothers Co., Utica, RIVETS PLATES HUB BALANCING TUBES CUSHION 3 THE IRON AGE, January 18, num- per select stant asing belts and ma- wild mper- had ABOVE 5—Polishing jack formerly used with set-up wheel has been converted for use with abrasive belt installa- tion floor model backstand idler. RIGHT 6—Steel motor cases being ground with coated abra- > sive belt having wall mounted backstand idler. the grinding surface permissible with the belt. the third group are the machines which approach pre- cision finishing status. Contact Wheel Surface finishing with abrasive belt usually requires cushion roll wheel under the belt provide resilient backing the point con- tact with the work. The the belt with contact (or com- press) wheel constitutes the function- ing elements some the machines especially fitted for surfacing rounded irregular shaped parts. Contact wheels are made canvas, leather rubber and can had num- ber densities, Fig. The cushion- ing effect the wheels contributes 7—Extending the usefulness bench grinder installing bench back- 52—THE IRON AGE, January 1945 stand idler and substituting contact roll for the grinding wheel. 4 towards proper cutting action per- mitting the belt conform the surface being ground, distributing the grinding action evenly over high and low spots. Contact wheels have suffi- cient firmness give positive belt drive and the same time prevent giazing and premature belt wear. The economical operation the belt de- pends the selection contact wheel that the appropriate den- sity relation the work. Converting abrasive belts from setup wheels accomplished sub- stituting contact wheel for the setup wheel and installing backstand idler. Fig. shows floor model backstand idler. can arranged for right left hand operation. idler for wall installation may some instances more convenient from point view space requirements, Fig. Because the long belt used, satis- factory heat dissipation obtained, preventing discoloring burning the piece being widths belts can used. Back- stand idlers have such fixtures lateral alinement and belt tension ad- justment prevent belt breakage and for smoother -also included safety device which pre- vents the belt tension from exerting too great pressure the belt when starting. i 1 ] | L | a pi 4 i per- the the and suffi- belt event The de- ntact den- from sub- setup idler. stand stand some from satis- ined, veral ad- and -also pre- from the 8—A belt type Fox swing frame mounting Metalite cloth belt for the removal weld seoms from armor plate. ° The factors involved converting abrasive belts from setup wheels are brought out actual case history. the result survey coated abrasives methods engineers the plant automobile manu- facturer making 155 mm. artillery projectiles, battery setup wheels were converted over belts. the belt finishing method projec- tiles were handled the rate per hr. against per hr. the set- wheel. Each belt was good for projectiles before was replaced Grinding the beveled edge: armor plate with specially designed belt sander with coarse grit (No. 24) heavy duty Metalite cloth. cost 62c. whereas the setup wheel averaged projectiles before was necessary replace glue and abrasive grain cost, including labor, The cost finishing was low- ered from 14c. 3c. per projectile. the numbers projectiles ran into hundreds thousands, the savings accrued made many times for the modest installation investment. Bench grinders may converted for abrasive belt application using contact wheel and bench back- stand idler, lathes also can converted abrasive belt grinding through the use this same unit. contact wheel roll semi- soft density generally satisfactory for application the bench grinder lathe. Complete bench backstand units with idler and jack are likewise available. such cases the idler unit mounted substantial base equipped with slotted holes line the idler the required distance from the jack arbor. Floor type backstands are manu- factured such companies Wy- THE IRON AGE, January 18, 1945—53 | } | song Miles Co., Greensboro, C.; Neiderst Co., Chicago; Mattison Ma- chine Works, Rockford, and Di- vine Brothers, Utica, Both floor types and bench model backstands are the products the Hammond Machinery Builders, Inc., Kalamazoo, Mich.; Jones Engineering Co., Elwood City, Pa., and Porter- Cable Machine Co., Syracuse, Porter-Cable also makes wall unit. Swing Frame Grinder The swing frame abrasive grinder has broadened the applications the abrasive belt making adaptable the surfacing hot-rolled armor plate after pickling, edging armor plate, grinding out welds and numer- ous operations castings and forg- ings, Fig. such work these ma- chines will cut faster and remove more metal grinding wheels. One factor permitting re- duction grinding costs the better finish produced. “swing frame abrasive belt grinder rolls forward backward I-beam, and may swung any di- rection while the process grind- ing. Bars, billets and sheets can ground with equal ease and speed. the swing frame abrasive belt grinder, made Fox Grinders, Inc., Pittsburgh, the belt operates over two pulleys—an adjustable idler and con- tact roll. The power hp. motor transmitted directly the contact roll means V-belts run- ning over sheaves. The abrasive belt alined means control within easy reach the operator and tightened automatically. The stand- ard roll has in. face and in. diameter. abrasive belt size 54—THE IRON AGE, January 18, 1945 ABOVE Finishing the slot para- chute hardware with specially designed belt machine. RIGHT de- burring unit using belt. Note how the operator controls the tension, hence the flexibility, the belt press- ing pulley arm. 141 in. used. The belt speed approximately 7000 ft. per min. The Jones Engineering Co., Ell- wood City, Pa., makes swing grinders three models: No. 300, with hp. motor; No. 307, with hp. motor, and No. 3110 with hp. motor. The Jones company supplies pedestals for each size grinder when desired have stationary mount for the grinder, when grinding welds from pipes. The heavy duty grinder shown Fig. utilizes leather belt moving over platen. This eliminates friction and provides cushion and support for the abrasive belt. means guide backing flat portion the belt does the cutting thereby permit- ting more accurate control the sur- face produced. This machine has been especially designed sand the beveled edges armor plate. The second group machines discussed makes use the various degrees which abrasive cloth belts are available. All cloth backings are especially woven and treated overcome stretch. Belts having maximum flexibility are used when required rotate around battery specially designed belt ma- chines finish the slot parachute hardware. Here the belt goes around thin spindle which can enter the slot. the most popular the abrasive belt machines the de- burrer, used for quickly removing burrs left from sawing shearing structural shapes, such angles, ties and channels (Fig. 11). the die castings, prior the ad- vent this machine, the trimming the light burr “lace” had accomplished hand filing scrap- ing. These jobs can now done fraction the time formerly re- quired using deburrer with nar- row belt, with without platen. government arsenal, manufactur- ing rifles, remarkable increase production resulted when hand filing was abandoned for abrasive belt de- burring machines. Belts varying from in. can used. Inexpensive belt platens various radii can made for ac- curately grinding radii and concave surfaces. Irregular can ground the portion the belt a | | | tur lar ers the pol Spl j dey ing sm | the de- the ad- nming scrap- one re- nar- ase filing elt de- in, can ens ac- oncave can belt above the platen. The table which comes these machines can tilted for grinding other than right angle surfaces. When finishing parachute buckle forging, the deburring belt reaches into corners and angles, leaving excellent surface. fixture may used that the slot the forgings can ground without re- moving the belt stopping the machines. Mead Specialties Co., South Market Street, Chicago, manufac- tures excellent, inexpensive de- burring unit which enjoys great popu- larity. Hammond Machinery Build- ers, Inc., Kalamazoo, Mich., offer their Model F-2, flexible belt grinder- polisher, which has heavy frame, spring belt tension and belt tracking device, and sealed-for-life ball bear- ings. Especially practical for grinding small radii unit manufactured Stuart Industries, Inc., Bellevue Street, Newton 58, Mass. The Stuart Abrazor fits all drill presses with up- right columns from in. and swings out the way when not use, thus leaving the drill press im- mediately available for normal func- tions. The abrasive belt moves around spindle that times faster than the drill press spindle. Small radii and other intricate places can reached without machine setup. Wet Belt Surfacing Waiter other coolants can used abrasive belts avoid heating and warping, flowing temper change. possible for un- skilled operator attain tolerances LEFT Porter- Cable model G-8 wet sander duction use. The job actually being done wet though the water does not show. BELOW the sanding rooms large war plant where girls are em- ployed for deburring the edges various small parts. The two machines the far side the room are Porter-Cable G-4 wet and dry belt surfacers. +0.0005 in. using the wet belt sur- facer which came into the field after the coated abrasives manufacturers provided waterproof abrasive belt. Besides eliminating the dust and fire hazards, much longer belt life can had the wet belt method. The wet and dry belt surfacing ma- chines, Figs. and 13, are the prod- uct the Porter-Cable Co., Syracuse, Hammond Machine Builders, Kala- mazoo, Mich. these machines, water sprayed the belt after has rounded the upper pulley. This prepares the cutting face the belt for its job cutting passes over the platen. The steady flow lubri- cant over the face the belt retards loading which, turn, results cooler, freer cutting action. also results better finishes and longer belt life. the belt rounds the bot- tom pulley, the working slush thrown off its surface force. Many pieces that might otherwise considered light grinder, miller and shaper jobs can done free hand the belt. The entire piece can applied the belt and all raised sur- faces ground the required level the same time, illustrated Fig. 12. For this cutting operation, coarse belt selected give finish that free cutter tool marks, burrs. Subsequent finishing op- erations are unnecessary, unless finer finish required. Much time saved getting job into produc- tion less setup and lockup time consumed, since the cutting ele- ment moves one direction and does not present the problem strain. When working close tolerances jig simple design may utilized. The greatest saving time based Slve loth and used mall ma- | j the capacity the flat belt sur- face large areas one operation. illustrate this gun mount bearing formerly faced lathe the rate per hr. now being surfaced the belt rate per min. Porter-Cable and Hammond Ma- chinery Builders both provide models which may used wet attaching the city water line and draining di- rect the city drainage system. These machines are equipped with recircu- lating systems which permit their op- eration independently the city water line and drain, when de- sirable use commercial coolant. Provided also are variety platens, among which will found those ac- curately surfaced for precision work and, equal importance, oscillating with micro-adjustment. For surfacing steel aluminum oxide cloth belt recommended, such Metalite cloth. Magnesium alloys are ideally suited the wet belt method, since the cool- ant makes possible surface and shape the material rapidly and with- out distorting even thin sections. For magnesium, aluminum and other soft metals, waterproof silicon carbide belt, such Speed-wet Durite Cloth, done wet with commercial cool- ant. Where the operation handled dry, regular silicon carbide belt recommended. For the sand- and finishing glass, tile, plas- 14—Finishing the head torpedo vertical abrasive belt machine. tics, and other ductile materials, sili- con carbide belts are preferred, using the waterproof the dry type accord- ing the operation hand. Shown Fig. specially de- signed vertical sander for finishing large, odd-shaped torpedo tube head. high degree surfacing precision has been made possible using jig table and controls. Powder Brazing Alloys for Tipping Tools tipped tools are generally tipped preplacing strip brazing alloy, together with suffi- cient amount between the tip and the shank. The assembly then placed furnace heated with induction coil. This procedure, how- ever, sometimes objectionable, the foil may become tarnished oxi- dized and then require temperature considerably above its own melting point flow freely. Experiments have proved that the use alloys powder form presents certain advantages over the use silver brazing alloys the form foil. Two silver-copper and one cop- per alloy are now available fine powder form for tipping tungsten car- bide and high speed steel tools. These alloys are economical use since the required flux mixed with the pow- dered alloy. This eliminates any waste flux during preparation. Then, too, and high speed steel 56—THE IRON AGE, January 18, 1945 the powder does not require the spe- cial handling necessary for cutting the foil into small pieces for exact preplacing. speed steel tip brazed low alloy shank with EutecRod 1800 powdered copper alloy, showing the clean joint obtained. These alloys are the product the Eutectic Welding Alloys Co. and are known as: EutecRod 1800 (lowest melting) for EutecRod 1601 (high tensile) for sten carbide 1020-1250 deg. EutecRod (high tensile heat resistant) for tungsten carbide 1300-1750 deg. (furnace temp.) After the customary degreasing and grinding, the powdered alloy spread the surfaces joined and the tungsten carbide tip placed top. The assembly then heated until the alloy melts. The metal flows freely very slight increase temperature above the melting point since the weld metal pulverized. Oxidation the tungsten carbide prevented, each particle molten alloy immediately “tins” and adheres the surfaces being joined. Many manufacturers tipped tools have already adopted this new process. specit equip have tory turer mens No. ment are i i 4 | £ jig ELIABLE determination specifications for steel requires specimens. Two equipped for preparing specimens have been furnished the Brown Sharpe Mfg. Co. for use the labora- tory prominent steel manufac- turer. Moore Standard fatigue speci- mens have the radius ground No. universal and tool grinding ments for this work shown Fig. are that the form must radius approximately in., and that the direction the grinding wheel marks will parallel the axis the The method employed for doing this Fatigue and Tensile Test Specimens Prepared Grinding job has the grinding wheel located above the work and rotating right angles the direction rotation the specimen which rotated dead centers and located proper rela- tion the grinding wheel table adjustment. Vertical adjustment the grinding wheel head used for stock removal and sizing. Truing the straight grinding wheel done mounting wheel truing fixture the table and man- ually traversing the transverse wheel head slide. This method can used grind any radius within the range wheel diameters the machine. grinding machine arranged grind A.S.T.M. in. tensile test pieces. Re- quirements for this work, shown Fig. are that the form will 0.505 in. diameter the center and 0.507 in. diameter each end the form, then going off deg. into space. The method utilized plunge-cut grinding with formed grinding wheel, the work being rotated dead centers. The form produced the grinding wheel moving the lower stylus the truing attach- ment, which the table, past the master form which mounted bracket fastened the bed the ma- chine. The forming movement power table travel. The slide the truing. attachment, which holds both the diamond and the stylus, kept contact with the master former spring. After truing the wheel, the table UPPER LEFT for grinding stand- ard fatigue test universal tool grinder. LEFT Plain grinding machine with special dressing plunge grinding tensile men. Wheel shown dressing position. ABOVE 2—Relation wheel work grinding Moore stand- ard fatigue test specimen. moved the right against posi- tive stop, thus positioning the work ready for grinding with the inde- pendent automatic cross feed. This method gives uniform reproduction the form regardless wheel wear. Any form can ground this method provided that portion the form greater than deg. angle with respect the center line the work. BELOW 0.505 in. tensile test specimen formed plunge grind- ing. THE IRON AGE, January 1945—57 | ng- Tipped High Speed Steel NDER the pressure wartime necessity and material short- ages, many firms during recent years have resorted using even such common cutting tool materials 18-4-1 high speed steel the form tip rather than solid shank form. Numerous articles have ap- peared the technical press describ- ing these methods, but was not apparent how extensively these practices were actually being applied. find the answer questionnaire was directed about 1500 plants the metal working industry, princi- pally those manufacturing machinery various kinds and transportation equipment, including automotive and aircraft manufacturers. Both large and small firms were canvassed, but none smaller than capitalization $100,000. Although the questionnaire was rather lengthy, was such form that answers could readily indicated merely placing check mark the particular type prac- tice material being used the plant making the reply. realized, course, that questionnaires have been the bane industry for the past several years, but was felt that directing these questionnaires the work managers smaller plants and the tool supervisors large plants would possible obtain fairly high percentage replies. Unfor- tunately this proved not the case; replies were received from about per cent those canvassed. can safely assumed that many did not reply because they were not using these conservation though the percentage returns was low, sufficient data were accumulated indicate that these practices are fairly widely used industry and that many companies plan continue these conservation practices after the war has relieved the strain the supply strategic metals like tung- sten, chromium and cobalt—as will seen later, however, not all con- sidered the conservation materials the primary objective, putting cer- tain operating advantages ahead this factor. While the chief purpose the sur- vey was discover how extensively 58—THE IRON AGE, January 18, 1945 high speed steel was being used tipped form single point cutting tools, was obvious that other data would uncovered relating ce- mented carbides which are normally used tipped form and the ques- tionnaire effort was also made find out what other methods con- serving material, extending tool life, were being employed. Unfor- tunately, retrospect, the question- naire appears ambiguous the ex- tent that the beginning did not limit the questions too specifically high speed steel tipping About one-third the replies, for instance, dealt solely with carbide tipping practice. Fig. summarizes the answers given question No. “Does your company make the prac- tice use the following cutting tool material tipped rather than solid form?” can seen, based 141 re- plies, the answers divide roughly the high speed steel tipped form. surprising note that many fewer companies tip the molybdenum types high speed steel. This in- consistency may accounted for due the question not being fully under- swers the question: your company make the practice use the tipped rather than solid YES Cast Grades Non- errous High speed steels stood. One reply had the word “Moly” written place the cobalt grade. interesting note that three companies reported using only the cobalt grades high speed steel tipped form. aside, might pointed out that recent article THE IRON AGE, was shown that high cobalt, high speed (up per cent Co) hardened few points above the Rockwell hardness gen- erally specified, gave almost double the performance life over solid high speed steel tools when cushioned type braze was employed. About per cent those reply- ing indicated that the cast non-fer- rous materials like Stellite, Rexalloy, and Tantung were being used tipped form rather than solid shank. much higher percentage would nor- mally expected. answer the next question, when tool tipping was started conservation measure, most the companies reporting tipping high speed steel indicated that they had begun between 1940 and 1942. fact, the largest group manufacturers started adopt this procedure about two years ago. Surprisingly enough those manu- facturers who reported using cast non-ferrous metals tipped form, indicated that they had done only within the last few years also, al- though one reply read, “Since Stellite was first marketed.” The question it- self was poorly phrased since was double-edged, reading, “When was tool tipping started conservation measure?” Several put down forth- right “Never” this one and im- plied, thereby, that tipping was done for some other reason than save expensive, high alloy material. Tool Types Distinguished Findirg out the extent which tipping high speed steel applied class tool proved somewhat dif- ficult—and there little doubt that the figures cited below cast non- ferrous grades are included well high speed steel, since provi- sion was made differentiate them. The question was divided four types: Single point tools (lathe, > pla too con ext too big pin les st Widely Used, Survey Shows \ planer), dovetail form tools, flat form tools, and other types, which each company was asked name. companies reporting the extent tipping single point lathe tools, firms applied tipping per cent their tools less, from per cent their tools, and shops per cent over. The biggest group—namely 8—applied tip- ping per cent the single point tools used. lesser extent, tipping applied planer and shaper tools. The this score are too spotty tabulate. Out firms which reported tip- ping only the cast non-ferrous grades, applied tipping per cent less their single point tools; 12, from per cent inclusive; from per cent; and from 100 per cent. the returns reporting tipping high speed steel dovetail form tools, tipped from per cent such tools, the remainder from 100 per cent. Most the reports the latter category tipped the cast non-ferrous materials well high speed steel. Out dozen firms which tipped dovetail form tools with the cast non- ferrous grades, but not with the amounts ranged all the way from “some” 100 per cent, with three- quarters them applying tipping per cent less this class tool. The survey showed that firms tipped flat form tools with high speed steel (some with cast non-ferrous materials also). these applied tipping practice per cent less their tools. the remaining applied tipping per cent more their flat form tool requirements. Out the shops which reported tipping tools with the cast non-fer- rous cutting metals (but not with high speed steel) noted that they applied tipping flat form tools. these, tipped per cent less these tools with this material. the remaining 10, tipped per cent less these tools and tipped 100 per cent their flat form tools with this grade material. ° FRANK OLIVER When the supply alloying elements for high speed steel became critical couple years ago, many methods using this cutting tool material tip rather than solid form were pub- licized. discover what extent these practices have actually been put work industry, survey was conducted, the results which are summarized this report, first presented before the 1944 annual meeting the The American Society Mechanical Engineers. Included the miscellaneous types tools tipped with high speed steel were listed counterbores and reamers, circular form tools, milling cutters, multiple planer tools, boring bars and special form tools. Milling cutters predominated, but the total number firms reporting this phase ac- tivity was small. Milling cutters and circular form tools also predominated among the “other type” tools tipped with the cast non-ferrous metals. Many these tools are purchased today tipped form, but large per- centage those reporting stated that they tip their own tools with either high speed steel bits with the cast non-ferrous grades. Brazing Methods Described Tipped cutting tool materials may brazed low alloy shanks sev- eral methods, one more which may and often employed the same plant. Discounting those firms that were apparently reporting ° ° 1G. 2—Number mentions meth- ods currently being discussed for ob- taining improved tool performance and generally longer tool life. Sub-zero treatment |35 practice only, the tally showed the following: Low temperature brazing (sil- ver soldering) Copper brazing High temperature brazing (ferro-alloy cement) .......18 The most proprietary brands silver solder and equivalent low temperature alloys recorded were Easy-Flo No. Sil-Fos (phosphor silver) and Castolin Eutectic Nos. and 1800. Cinch Steel Cement, Cru- moid, Tip-it and Ferroid flux were mentioned proprietary brands high temperature cements. According this survey, heating with oxyacetylene torch far the most widely used method heat- ing the shank prior tipping. This was expected, since the simplest and cheapest method. There were check marks this method heating, compared with for use muffle furnace and for induc- tion heating. There was one mention salt bath heating. Question Heat Treatment Most shops that reported tipping high speed steel with silver solder, using the oxyacetylene torch for heat- ing, indicated that subsequent heat treating the tip required, al- though several gave the tools slow cool lime Sil-O-Cel. Although the melting point the silver solders, 1300 deg. somewhat above the temperature required for drawing high speed steel, the time that temperature short that subse- quent heat treatment not needed. course, annealed stock used for the tips, these must hardened before brazing takes place. More often than not, salvage pieces high speed steel, including worn inserted THE IRON AGE, January 18, 1945—59 e ' ° ° ° | oly” ade. hree the ticle that per ints uble high ank. nor- the high had and this anu- cast orm, only it- was im- done save al. hich that well four tooth millirg cutter blades with the serrations ground off the back, are frequently used for tipping single point cutting tools. Where the brazing done muffle furnace, either single draw 1050 deg. double draw, first 1100 deg. ard then 950- 1000 deg. F., given the tool after brazing the same furnace. Only one concern reported the use subzero treatment tipped tools after brazing—drawing 1030-1050 deg. after quenchirg from the brazing temperature, then freezing —90 deg. F., followed draw 980-1000 deg. F., and second freeze the same low temperature. High temperature brazing with ferro-alloy cements like Cinch, Cru- moid, Tip-it require the same heat treatment for hardening solid high speed steel tools. After the cemert powder has been applied, the shank and tip are preheated 1600 deg. F., then brought the hardening temperature for the particular grade tip. Upon withdrawing the tool from the furrace the surplus cement squeezed out hand arbor press and then the tool quenched oil air. Pressing the tip place gives sufficient adhesion allow the tool handled safely. quote this comment, presented some length, because runs counter general experience disclosed this survey: “The salvage tool steel ma- terials has been practiced this com- pany ever since the development low temperature brazing. The ends worn out solid tools are brazed to- gether, thus obtaining additional life. good results, however, have been tained tool tipping, since the melting point the low temperature brazing medium near the draw cult control, especially when consid- the present manpower that avail- able. “Toolholders, which tips are held place clamping, are used the toolroom, but are rarely used pro- duction, due the larger size, difficulty stricted heat transfer comparison the solid tool. “Stellite type tipped tools are used great extent, but the use carbide tipped. tools far greater, with the drawback, however, that the latter can- not ground the operator, but must maintained the tool grinding de- partment. “The use solid Stellite type tools since the upkeep abrasive parting wheels overshadows the economy Stellite tipping, considering the mainte- nance these tools. All tools over however, will continued tipped ools.” Welded Tipping Practice The question was also raised whether tips were welded low alloy shanks and what process and using what type welding rod. Replies this question were con- fused some extent. Since even the manufacturer Castolin Eutectic 60—THE IRON AGE, January 1945 alloys refers the process weld- ing rather than brazing silver soldering, not surprising that users listed this method tipping either welding brazing. For the purpose this survey, however, these materials are better classified under low temperature brazing. shops which tip high speed steel and the cast non-ferrous mate- rials and which use the welding tech- nique, employ gas welding and are welding, including each group that weld either way. the com- panies that limit tipping the cast non-ferrous materials, reported the use welding, seven the gas technique and five both gas ard arc. The type rod electrode listed varies over the whole range pos- sibilities, from ordinary low carbon steel Stellite, probably applied facing material. High speed steel rod far the most popular for welding that class tip. Trade names mentioned include Gorham, Suttonite No. American Agile, Eureka 70W and 71M and Toolweld. Stainless steel apparently suitable for welding both high speed steel tips and the cast non-ferrous grades. Be- ing autenitic character, does rot harden and leave brittle weld. Nickel was named one blank and No. 1215 air hardening rod an- other. answer question concerning heat treating procedures following welding, the replies were few and spotty. Most irdicated that none required and while this obviously the case for the cast non-ferrous grades, which are not affected the welding heat, equally obvious that both gas and are welding would draw the temper high speed steel unless the low temperature welding alloys are employed. only two blanks was: irdicated that after welding, the tips are heated locally 2200 deg. and then oil quenched allowed cool air, followed draw 1050 deg. The question, “In general, are higher hardnesses employed tipped tools than solid high speed steel tools?” apparently was badly phrased, judged from some the responses obtained, particularly the light the Rockwell hardness values noted. Four noted hardnesses around 90, for example, which Rockwell scale value for the carbides. would expected, for the cast non-ferrous materials the same hard- ness used both tipped and solid tools. Thirteen replied that higher hardnesses were sought high speed steel tips than the solid tools. Two specified hardnesses the range TOTAL REPORTING Number reporting 3—Extent which companies report the substitution cemented carbide cutting tools for high speed steel machining cast iron. ° ° 65-68 Rockwell one 67, three 66, and six Re. Higher hard- nesses can safely employed the tip since there danger crack- ing the shank, which may heat treated give strength and tough- ness resist clamping loads and cut- tirg shocks. Longer tool life can expected from the harder tip. Shank Materials Earlier, mention was made tip- ping the high alloy cutting tool ma- terials “low alloy” shanks. must confessed that when data was re- quested the questionnaire what this shank material might be, was expected that not more than three four steels would named. Instead, there were over dozen. the descending order number mentions, shank steel actual use range follows: No. Specification Reporting Shank steels mentioned only trade name included: Maxel, Silman, Solar, Cyclops 67, Beacon, Sander- son carbon steel, and Braze Rite. Most tips are brazed milled bars, al- though about one-quarter those re- plying this question indicated that they tipped forged bars well. semblance order the sizes shanks which are being tipped today. They range all over the map, the survey indicates, from in. cutoff shop listed 3/16 in. This probably applies tools the drill rean cour ture requ | 100- | ping misi SAE 1050 and higher C.... (12) whic SAE 4140-50 (5) SAE X111 (2) One that spee ping and reamer type which are “tipped” flash butt welding. this connec- tion, only eight returns checked the use resistance flash butt welding, applied the few cases noted small rounds and squares, end mills, reamers and drills. realized, course, that this method manufac- ture employed almost 100 per cent makers high speed steel twist drills. Answers the question, “What per cent your high speed tool steel requirements have been saved tip- 4—Extent which companies report the substitution carbides for high speed steel machining non-fer- rous REPORTING Number reporting ping?” the writer feels sure were misinterpreted some cases. Some undoubtedly ha