The Iron Age 1945-01-25: Vol 155 Iss 4

ond Jehnson, Market Research Heyes, Typography and Leyout Business Managers WARRE Les Angeles Cheremoya Ave. Owned and CHILTON COMPANY Executive Offices Chestnut and Séth Philadelphia Pa., OFFICERS AND MUSSELMAN, President HILDRETH GEORGE EVERIT TERHUNE Vice-President BARBER, JOHN BLAIR MOFFETT, CHASE THOMAS KANE HARRY DUPFY HEALE ° Member, Audit Bureau Circulation South America and Cable Vol. 155, No. The AGE January 25, 1945 Editorial Technical Articles Flash Welding SAE 4130 Steel Tubing Large Scale Working Adirondack Magnetites Optimum Plate Width Detemmination Physical Properties Brass Powders Extrusion Bent with Self-Locking Form Blocks ......... ° ° ° Features ° News.and Markets Brazilian Aluminum Looks 102 112 Lakes Cargo Tonnage Record ........................ 114 Canadian Pig Iron Output Declines 116 Steelmaking Improvements 118 British React American Criticism 124 Machine Tool Market Developments 134 Non-Ferrous Metals News and Prices............... 136-137 Iron and Steel Scrap News and Prices............... 138-139 Comparison Prices Week and 140 Finished Iron and Steel, Steel Prices................ 141 Warehouse, Semi-Finished, Tool Steel 142-143 Steel Pipe, Tubing, Wire Prices............ 144-145 Stainless Steel and Ferroalloy Prices 148 ° Naw York New York eveian Pittsburg vt LEWIS RAYMOND KAY | | i Member, Associated Business Papers a 7 save time and money use the RIGHT bar When specifications call for bar steel, phone Ryer- son. save time, trouble and get the bar exactly right for your Ryerson stocks include practically every shape and size bar, practically every analysis steel now available. Whether its straight carbon alloy, hot rolled, cold finished heat treated, Ryerson has the right bar nearby stock and will ship once. Why elsewhere when the nation’s largest steel stocks are your surest source for just the bar you need. you have question steel selection application, experienced Ryerson metallurgists and engineers will glad work with you. There obligation. Inquiries well orders receive prompt attention. Ryerson Bar Stocks Include: Aircraft Alloys Forging Quality High Carbon Round Edge Allegheny Stainless Free Cutting Hot Rolled Screw Steel Alloy Gagger Bars Mild Steel Shafting Bevel Edge Galvanized Alloys Spring Steel Carbon Steel Hexagons Octagons Stainless Coal Screen Half Ovals Ovals Stressproof Cold Finished Half Rounds Pickled Steel Cold Twisted Heat Treated and Oiled Threaded Forged Hi-Steel Reinforcing Tool Steel Shapes, Plates, Sheets, Tubes and many other products are also stock for quick shipment. Son, INc. Plants: Chicago, Milwaukee, Detroit, St. Louis, Cincinnati, Cleveland, Pittsburgh, Philadelphia, Buffalo, New York, Boston. Presi RYERSON STEEL-SERVICE 4 : * IRON ESTABLISHED 1855 ° ° Jan. 25, 1945 President and Director BAUR Vice-President and General Manager ° ° ° Editorial Staff LIPPERT Technical Editor ........ OLIVER ° Associate Editors WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Editorial Assistants DAVIS News and Technical Editors LLOYD Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bldg. LLOYD Cleveland 1016 Guardian Bidg. BRAMS Detroit Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS JAMES DOUGLAS Seattle Time Saving AYLIGHT saving, like most everything else, not modern innovation. According the Bible was invented Joshua, who, are told, made the sun stand still that could finish the job demolishing his enemies. was great asset that Joshua possessed being able manage the clock that could have the necessary time finish his work. Many today would like have the ability declare similar moratorium time. true that Mr. Roosevelt has given the benefit daylight saving which bemoaned our schoolboys who have trudge their daily recitation the three “R’s” during Nature’s morning black- out and our farmers who cannot get their cattle imbued with the war spirit. has, aside, also been moot question among those who oper- ate work night shifts these days when factories are hour shifts, who gets what from clock juggling. Everybody gets the dark and goes home the dark regardless the shift which works. not registering complaint with respect time saving. for that 100 per cent and are the great majority doers this country who have been brought try to. pack more and more into each minute time goes especially now, when are war, think that time saving the very essence. The point that wish make, can, that not save time, nor you lose moving the hands clock back forward. The only way that you save time make possible for people accomplish more given time interval. What thinking about the enormous waste time that has been wished upon busy executives this country through the regula- tions which compel them spend almost endless hours filling out reports, forms and applications that have little nothing with helping win the war but much with detracting from the effi- ciency the war effort. Detracting from because this work, and believe work, takes their minds completely away from the pri- mary task war production. will pass over such matters preparing income tax reports, social security statistics, renegotiation theses and priority applications and get down the case Mary Jones. Mary Jones clerical worker whom thought was deserving raise. She had been the job several years, had stuck well and faithfully and had like most other office workers been under increasing pressure during that period. The idea was get Mary raise $3.00 per week. Under ordinary circumstances the management could have done that one minute with stroke the pen. But times are different. The work preparing request for this raise submitted the War Labor Board took total time hours two very busy executives who otherwise might have been doing something help win the war. Maybe she will get and maybe she won’t. the latter case she will probably quit and some place where she can get what she worth thereabouts which case will lose not only Mary but the executive hours work well. There’s old saying: “Penny wise and pound foolish.” But who pays any attention old sayings? SCHIEN VAN CAMP MUNZER O'CONNOR MILLER . 44—THE IRON AGE, January 25, 1945 Measuring enamel thickness with electric gauge. Another New Creation Inland Steel Company’s Research The long awaited porcelain enamel- ing base, which eliminates the neces- sity for ground coat, here! Ti-Namel, the new titanium allo steel—the newest creation Inland’s research laboratories. Ti-Namel superior every re- spect older types base metals. drawing properties are equal the best deep-drawing steels. does not age strain matter how long remains storage before fabrica- tion. Inland Ti-Namel Steel does not reboil. Therefore vitreous enamel finishes, equal the best multi-coat ware, are obtained with white color coat enamels applied direct the base metal. This results thinner coat which reduces chipping Laboratories INLAND STEEL hazards and increases the service- life the ware. Ti-Namel edging, and scrap. fired lower temperatures, and less time. short, Inland Ti-Namel Steel in- creases shop output, lowers manu- facturing cost, and assures superior vitreous enameled ware. patent applications the new enameling and product made thereby, are owned jointly Inland Steel Company and The Titanium Alloy Manufacturing Company under trust agreement. Write for copy the Ti-Namel Bulletin and licensing agreement. Inland Steel Company, South Dearborn Street, Chicago Illinois. Sales Offices: Cincinnati, Detroit, Kansas City, Milwaukee, New York, St. Louis, St. Paul. The ximat The lors. truly The The The diti Bien ion ura let News The German "Foo Fighters" were said last week Army Transport pilots electricity, St. Elmo's fire. About per cent German steel production lies the Ruhr Valley and per cent the Saar. Saarbrucken, captured last month the has two blast furnaces and extensive coking plants. But: Allied armies must knife into Germany for more miles before production will below essential military consumption. traces boron have yet been found the alloy steel captured German even with the most accurate spectroscopic examinations. The original Iridite colored coating for steel, controlled Rheem Mfg. Co., been supplemented other colors, obtained dyeing the basic olive drab ting. Iridite Black being widely employed, Red, Blue, Green, and Flavine very recent addition Iridite Bronze, basic coating that truly rich bronze hue having excellent characteristics. The Japanese have announced the loss Admirals combat. This figure compared with total 312 Admirals the much larger American Navy. The rising costs British production exemplified the announcement that motorship 9200 tons would have cost $340,000 1936, while today nilar vessel would cost $900,000. The cigarette ration Germany two per day, and cigarettes will buy any- the black market. Cigarettes are even very scarce the Wehrmacht. German working hours are now generally fixed hr. per week. Eight dif- wage groups have been established, with basic wage for each group, and ditional bonuses geared individual output. The Michigan Manufacturers Association and the UAW-CIO are lined against War Manpower Commission the debate concerning Detroit's take war jobs. The auto union claims that employment Willow Run has dropped from 40,000 recent months, that Briggs has laid off about 12,000 and Murray more 6000 support its position that labor shortage does not exist Detroit. spite WMC's insistence that labor shortages exist Detroit, war mtracts for tanks and other ordnance vehicles and preliminary work signifi- aircraft developments are being placed. The omission scrap yards from the latest list essential work may make situation more serious. Scrap yards have been suffering from dearth for some time and further exodus workers seeking draft deferments will ikely result critical supply situation. And: has even been predicted that open hearths may forced shut down lack scrap this situation left unchecked. The current ownership passenger automobiles has uncovered defi- corrosion protection, which are the subject considerable ion among car builders. And: The breakdown parts has led the promise that auto akers will provide future owners with plating better quality and increased $8,000,000 zinc refinery prospect for the Pacific Northwest survey American Smelting Refining Co. The plant will likely Tacoma and will employ about 1000 people. The automobile industry turned out more than million dollars worth ent hour during 1944. That amounted $9,320,000,000 for the year, per than was made 1943. Aircraft and aircraft parts accounted for $4,200,000,000; vehicles and $2,500;000,000, and tanks and tank parts, $1,050,000,000. 23, 1945 € q | Measuring enamel thickness with electric gauge. Another New Creation Inland Steel Company’s Research Laboratories The long awaited porcelain enamel- ing base, which eliminates the neces- sity for ground coat, here! Ti-Namel, the new titanium alloy steel—the newest creation Inland’s research laboratories. Ti-Namel superior every re- spect older types base metals. Its drawing properties are equal the best deep-drawing steels. does not age strain matter how long remains storage before fabrica- tion. Inland Ti-Namel Steel does not reboil. Therefore vitreous enamel finishes, equal the best multi-coat ware, are obtained with white color coat enamels applied direct the base metal. This results thinner coat which reduces chipping hazards and increases the service- life the ware. Ti-Namel reduces reoperations, edging, and scrap. fired lower temperatures, and less time. short, Inland Ti-Namel Steel in- creases shop output, lowers manu- facturing cost, and assures superior vitreous enameled ware. patent applications the new enameling and product made thereby, are owned jointly Inland Steel Company and The Titanium Alloy Manufacturing Company under trust agreement. Write for copy the Bulletin and licensing agreement. Inland Steel Company, South Dearborn Street, Chicago Illinois. Sales Offices: Cincinnati, Detroit, Kansas City, Milwaukee, New York, St. Louis, St. Paul. INLAND STEEL 44—THE IRON AGE, January 25, 1945 The tic Abou ximat The The The Bing rent | abor ike] | News The German "Foo Fighters" were said last week Army Transport pilots electricity, St. Elmo's fire. About per cent German steel production lies the Ruhr Valley and per cent the Saar. Saarbrucken, captured last month the lies, has two blast furnaces and extensive coking plants. But: Allied armies must knife into Germany for more miles before production will below essential military consumption. traces boron have yet been found the alloy steel captured German even with the most accurate spectroscopic The original Iridite colored coating for steel, controlled Rheem Mfg. Co., been supplemented other colors, obtained dyeing the basic olive drab Iridite Black being widely employed, Red, Blue, Green, and Flavine lors. very recent addition Iridite Bronze, basic coating that rich bronze hue having excellent characteristics. The Japanese have announced the loss Admirals combat. This figure compared with total 312 Admirals the much larger American Navy. The rising costs British production exemplified the announcement that diesel motorship 9200 tons would have cost $340,000 1936, while today nilar vessel would cost $900,000. The cigarette ration Germany two per day, and cigarettes will buy the black market. Cigarettes are even very scarce the Wehrmacht. German working hours are now generally fixed hr. per week. Eight dif- wage groups have been established, with basic wage for each group, and ditional bonuses geared individual output. The Michigan Manufacturers Association and the UAW-CIO are lined against War Manpower Commission the debate concerning Detroit's take jobs. The auto union claims that employment Willow Run has dropped from 40,000 recent months, that Briggs has laid off about 12,000 and Murray more 6000 support its position that labor shortage does not exist Detroit. spite WMC's insistence that labor shortages exist Detroit, war mtracts for tanks and other ordnance vehicles and preliminary work signifi- aircraft developments are being placed. The omission scrap yards from the latest list essential work may make situation more serious. Scrap yards have been suffering from dearth abor for some time and further exodus workers seeking draft deferments will ikely result critical supply situation. And: has even been predicted that open hearths may forced shut down lack scrap this situation left unchecked. The current ownership passenger automobiles has uncovered defi- corrosion protection, which are the subject considerable ion among car builders. And: The breakdown chromium-plated parts has led the promise that auto akers will provide future owners with plating better quality and increased $8,000,000 zinc refinery prospect for the Pacific Northwest com- survey American Smelting Refining Co. The plant will likely Tacoma and will employ about 1000 people. The automobile industry turned out more than million dollars worth hour during 1944. That amounted for the year, per than was made 1943. Aircraft and aircraft parts accounted for $4,200,000,000; vehicles and $2,500;000,000, and tanks and tank parts, $1,050,000,000. | 23, 1945 e 4 : ‘ - ‘ t YPICAL parts formed flash welding SAE 4130 steel tubing forgings. Top view: Hydraulic landing gear assembly; cen- ter, wing strut as- bottom view, door bracket. HILE SAE 4130 steel has good weldability characteristics, only recent years that the aircraft industry has extended flash welding this material. The advantages the flash welded joint over the fusion welded joint are follows: Better physical characteristics (100 per cent Lower weight. Cheaper and faster production with less operator skill required. (4) warping result welding. (5) Less brittleness low temperatures tudes. (6) Higher fatigue strength. Welded assemblies made from SAE 4130 steel may used without sub- sequent heat treatment. However, all types welding have effects the microstructure this steel which make heat treatment advisable wher- ever practical. One reason release locked-in stresses which are caused the contraction the metal upon cooling. Another that just adjacent the weld zone, por- tion the metal has been treated just slightly below the critical tem- perature, thus causing annealing effect. This may result per cent drop tensile strength. The third most important effect is, how- ever, that since chrome-moly air hardening steel, the fast cooling the weld results brittle zone next the weld. This particularly true flash welding where the chilling *Since this article was written, Mr. Ackerman died the service his country, 46—THE IRON AGE, January 25, 1945 effect the dies tremendous. With proper die spacing and correct ma- chine setting, all these effects can minimized the point where sub- sequent heat treatment can dis- pensed with. Co. reports that excellent physical test results have been obtained with weld- joints which the component parts have been heat treated 140,000 Ib. per sq. in. before welding, with heat treatment after welding. heat treatment after welding, the steel must the normalized state before welding. the present time, the major- ity applications flash welded joints are tubular sections. Typi- parts include end fitting weld- tube joint which the fitting may either forged turned down from solid stock, one tube an- other. The range areas welded may vary from less than 0.04 in. over sq. in. Design Considerations One the greatest hindrances flash welding the failure the various industries design their parts for flash welding. The net re- sult this that critical welds are obtained both from the standpoint complete fusion and weld brittle- ness along with bad alinement. The proper design part flash welded one which there suf- ficient clamping surface and length for die spacing with positive ma- chined backup. The main objection the aircraft industry the chang- ing the design that since the tubular section the forging must lengthened this necessitates addi- tional machining and change forging dies. the normalized state com- paratively low strength heat. ment, all component parts may finish machined before welding and the final assembly may held within customary tolerances plus minus 0.010 in. This course, with excellent flash welding design the part. While this close tolerance can requires more time for setup the shop and requires more skill the part the operator. Consequently the design should not call for tol- erance which does not have held, such any part which has thread- fittings one both ends. Welding Setup logical assume that the amount burnoff and upset are tions the wall thickness the tub- ing and should figured that rather than diameter area. The following table gives the approximate burnoff and upset fer various tubing wall thicknesses. Wall Total Total Thickness, In. In. In. 0.190 0.050 0.049 0.290 0.075 0.065 0.845 0.100 0.125 0.430 0.135 0.150 0.485 0.140 0.188 These the tions. mot However whether cylinder end the the that would lieve welds same the welc give also the tion the sions als the die the wel any bottom result critic bottom with One held the amoun tomed suffici tance. comm . | | 4 q 4130 Steel Tubing... These values are the best available the present time and should for almost all applica- motor driven flash welders, the upset easily set shim- ming the upset block the cam. there some question with hydraulic machines the cylinder should bottomed the end upset whether the resistance the metal further upset should the determining factor. The for bottoming the cylinder that gives definite take up. would seem logical, however, be- lieve that the best and most consistent can obtained exactly the same forging pressure applied the weld every time. Theoretically both methods should give not only consistent welds, but also definite takeup. This going the assumption that the composi- tion the steel does not vary, that the steel clean and that the dimen- sions not vary from piece piece the dies variation welding volt- age. The uniformity operation the welder also great importance. any these conditions are absent, bottoming the likely result faulty welds when welding steel like chrome-moly. Not bottoming the cylinder tend offset these certain extent but One two compromises must made all conditions are not held constant; either the quality the weld must sacrificed the amount takeup must suffer some variation. Upset Pressure the cylinder going bot- tomed, the upset pressure sufficient insure bottoming the the other hand, the the upset pressure major impor- tance. Although upset pressure the cross-sectional area, also ° WALTER PESTRAK, Senior Welding Engineer and ACKERMAN* Welding Engineer Federal Machine Welder Co. Warren, Ohio ° ° SAE 4130, with its sister steel 8630, has distinguishing char- acteristics which make particularly desirable aircraft steel, such excellent strength-weight ratio, good weldability and high tensile strength with good impact resistance. Practical considera- tions relating the flash welding this material are presented. really function the compactness the weld area. For example, take the two extreme cases, the one solid round section and the other tubular section very large diam- eter with exceedingly small wall thick- ness. Even though both these have equal cross-sectional area, would foolish use the same upset pres- sure and expect similar welds. determine the unit upset pres- sure the weld area, two things must taken into account: First, the type steel being welded and second, the difficulty extruding the molten metal from the weld. Unfortunately, very little known about just what the desirable pressure for various types sections. This much can stated. excessive pressure used, the effect upon the weld cause excessive brittleness and low impact strength along with probably incom- plete fusion but with quite high ten- sile strength. There are two ways which brit- tleness may caused the welding SAE 4130 and other alloy steels. The first cause the quenching effect due the fast cooling weld the chilling action the dies. Since most these steels are air hardening, the result brittleness the weld zone. The second cause brittleness less obvious and open some argument. ductile material one that will elongate rupture. This elongation obtained because the ability the grains the steel slip along each other. These grains can only slip far until rup- ture the result. after upset flash weld there excessive pres- sure during the cooling below the plas- tic temperature the metal, the net result that the grains have slipped much they are able and there- fore, due this cold working the weld more brittle than might have been. According the manual the Re- sistance Welder Manufacturers Asso- ciation, welds made with insufficient pressure are characterized porosity, inclusions, low strength and poor im- pact resistance. the welding chrome-moly steels, this statement open debate almost all points. welding 0.125 in. wall tubing, for example, the upset pressure was dropped 7000 per sq. in., yet when photomacrographs were taken, there were indications porosity inclusions. Probably mild steel which may contain many impurities, there would slag inclusions with too low upset pressure. Concern- ing tensile strength, all cases the low pressure welds broke outside the weld when the weld was tested the unheat-treated state. The out- standing characteristic the low pressure weld was its extreme ducility compared that high press- ure weld. every low weld there appears white line directly through the weld. According metallurgists this line may caused variety things and there are various opinions about whether not harmful. From work carried date, the be- lief that this line not harmful the weld used the un- heat-treated state, since the strength this white line more than that the parent material. ques- tionable whether with exceedingly high strength heat treatment this line will heat treat the desired proper- ties. summing the effect press- ure, the following recommendations are made. the weld used without further heat treatment an- nealing, minimum upset pressure should used, thus resulting ductile weld. However, annealing further heat treatment are order, the upset pressure should increased about three times the minimum value since the resulting THE IRON AGE, January 25, 1945—47 ry the om- eat- thin nus the the the ntly tol- eld, that nate brittleness will disappear with heat treatment and with increased pressure the white line not predominant. any flash welding, the speed upset very important with SAE 4130 steel. There are reasons be- lieve that the faster the upset the better the weld and perhaps the less pressure required. One reason, course, for desiring fast upset prevent oxidation the high tem- perature weld surfaces. Die Opening Since the chilling effect the dies quite large and has much influence upon brittleness the weld, the die opening should kept greater for SAE 4130 than for mild steel. Limit- ing factors which must taken into LEFT ROGRAPH flash weld SAE (X4130 steel). BELOW SCILLO- GRAM flash weld SAE (X4130 steel). account, however, are the design the pieces being welded, the ability hold alinement and very light wall tubing, the deformation the tubing under upset pressure. There some question whether the die opening should function the PLAN view Federal flash welder for welding SAE 4130, showing die and backup construction. 48—THE IRON AGE, January 25, 1945 table takes into account only tubi diameter but the data should well for all the common wall thic nesses: Outside Die Open- Diam. ing Tube, In. In. 9.375 1.00 0.500 1.25 0.750 1.50 1.000 1.75 2.00 1.500 2.00 2.125 2.00 Flashing Time Like burnoff and upset, the ing time function wall ness and quite critical the thin ner wall tubing. critical mon from the extent keeping con sistent flashing time after weld setting has been found than initial setting since cam desig machine operation, preparation bw as alues arge mace work and amount upset are all fluencing factors. Therefore, values given below can varied pending upon other conditions. mall Like flashing time, upset time function the wall thickness and good welds. For thin walled has been found necessary cut the current before upset order prevent burning off the tubing overheating the weld. the thicker tubing the current should kept until the upset completed and haps some annealing action might obtained left even longet. For heavy walled tubing, the lies more cutting off too soon than cutting off too late. Speed upset great influence upon the quired current carry-over. These values should serve general guide: Beli Thickness Time, Time, posi In. See. Cycles 0.035 0.049 4.5 0.065 0.083 7.0 the 0.125 10.6 10.5 give 0.150 15.0 pro 0.250 25.0 ‘ pee | | | : > - } | welding SAE 4130 steel, the voltage should kept possible. The customary pro- adjust the die opening, and upset distance, pressure, and upset time the desired and then increase the voltage until freezing encountered. The effect too secondary voltage and con- large flash particles out, thus not only leaving arge irregularities the weld sur- face closed up, but also result- all incomplete fusion the case SAE 4130. the start the flashing very mall particles are thrown out but the end large pieces metal and emitted, the fault lies not with but with the cam design. jer increasing the edges the tubing forging, the voltage hicker studies the structure and compositions for the hard-tipping cutting tools and the various meth- ods applying these materials, Minkevich, Yu. Geller and Belikova conclude that forged tips steel the following com- 4.0 Mo; 2.0 2.5 Va; 0.4 Si, and 0.4 max. Mn, when attached tool shank mechanical means the best results. These tips can dropped another tap. cam which has worked very satisfactorily for chrome-moly one which the beginning flashing has rise 0.0005 in. per deg. and the end flashing rise 0.0055 in. per deg. With such cam, desirable bevel the edge one tube angle deg. with the centerline the weld. Inspection Flash Welds the present time there conclusive method non-destructively testing flash welds. While extensively tried, X-ray inspection has showed promise has given little in- dication the strength flash weld. use the present time magnetic particle inspection Mag- nafluxing which has been slightly more successful that will re- veal very bad flaws due lack fusion but has not yet been able differentiate between good welds and those which, while contain- ing serious flaws, are considerably respect even superior, tungsten high speed steels, the authors report Metallopromyshlennosti, No. pp. 38-52. Cutting tips having chemical analysis 4.0 15.4 Cr; 6.0 Mo, 6.0 Va; 1.0 2.0 Si, and 0.75 were produced welding. soft iron electrodes with ferroalloy coating cast alloy electrodes with chalk-water glass coating were used. The structure the deposited. mate- rial was that ledeburite eutectic with large primary carbides. Another heavy duty flash welder for welding SAE 4130 chrome-moly and other alloy steels. below the desired strength. believed that the best available inspection method the close control the equipment and the process after the machine has been properly set up. One good method testing follows: the first lot each new part, four test coupons are pre- pared for each different weld. These coupons are identical the produc- tion parts with respect material and heat treatment, diameter and gage. Three the coupons are tested destruction tension while the fourth subjected microscopic ex- amination. addition coupon made and subjected the test load after each succeeding welds. failure any coupon below the test load during production run cause for the testing the proceeding lot welds determine their ac- ceptance rejection. the equip- ment the proper type and prop- erly qualified, this method will result obtaining 100 per cent satisfactory welds. Brazing Low-Alloy Tool Tips with Powdered Alloys alloy the same type, but containing less carbon and more vanadium, gave more uniform and finer structure. was found that welded tips were difficult grind shape their hardness could not appreciably re- duced annealing. Chill-cast tips these alloys and less highly alloyed compositions were produced for at- tachment the tool shanks braz- ing. These tips tended have cast- ing faults. Cutting tests the weld- and tips showed them inferior tungsten steel. THE IRON AGE, January 25, 1945—49 ollowiy £ mon : than design | Large Scale Working Mines abandoned years ago have been reopened, active mines greatly expanded activity and $40,000,000 worth modern mining and concentrating equipment has been produce high grade magnetite sinter from ores ranging from rich. Depletion high grade Lake Superior ores, and the fact that major steel companies are working these Adirondack ores, lend them new importance. the first port the article many the economic factors are compared order evaluate the per- manence this activity and its influence blast furnace practice. FRANK OLIVER activity the Adirondack area New York State has posed set new economic and technical questions blast furnace operators particular and iron and steel con- sumers general. The prime ques- tion relates the comparative cost beneficiated magnetites high iron content shipped via rail with respect lower grade Lake Superior hematites shipped water. This question cannot considered alore but must related that how serious has been the depletion the rich ores Minnesota and the Upper Peninsula Michigan and what will the added costs concentrating such ores. What these costs will ulti- mately anybody’s guess, but con- sidering present concentrating costs the Adirondacks added ton would the conservative side. increasingly large tonnage Lake ores are already being screened order remove fines and thus pro- duce more uniform product re- gards passage gas through the blast furnace. Sintering the fines the next step necessary make them usable the blast furnace. Whatver costs involved these pro- cedures today are absorbed within the present OPA ceiling prices $4.45 $4.75 per gross ton delivered lower Lake ports (51.5 per cent Fe), which $1.81 the rate. For Pittsburgh delivery $1.21 should added. But the cream the rich ores skimmed off, the cost IRON AGE, January 25, 1945 beneficiation. will naturally rise and will ultimately passed the consumer. Obviously, the increase the price such basic raw mate- rial will reflected right the line through pig iron and semi-finished and finished steel products. Don Gillies, vice-president Re- public Steel Corp., has that, Adirondack Iron Ore Mining and Metallurgy, November, 1943. taking into average rail rate $2.66 from Port Henry, (see Table I), the break-even point for cost Adirondack sinter (68.5 per cent Fe) compared with average cost Mesabi Lakes ore de- Mahoning Valley furnace $5.45 per long ton would $4.59 the mines. either case, the cost per long ton unit iron would delivered the mill. The indications are that such costs are presently being met will soon the newly built concentrating plants reach 100 ‘per cent capacity operations close it. Blast Furnace Economies There another side the picture which Mr. Gillies and point and Blast Furnace Thermal Principles,” Charles Agnew, Steel, Oct. 1943; also “Beneficiated Iron- Bearing Materials,” Agnew, Steel, out, namely, that use magnetite sinter place Lake Superior soft ores results many blast furnace savings. Republic mills, use high percentages (40 per cent) sinter the blast furnace raised production from per decreased coke consumption ap- proximately per cent, flux con- sumption per cent and cut per cent. These savings are explained the basis that porous sinter cake containing 68% per cent iron (1) re- duces the slag forming elements proportion the degree iron con- centration with corresponding benefit upon the fuel rate for smelting, pro- ductive capacity and the problem slag disposal and (2) the use heavier burden and higher blast tem- peratures (but with much less gas volume) results more efficient fuel utilization. soft ore practice, the greater volume gas created the hard blowing rate and the lease the volatile elements con- tained in_the soft ores. the sinter- ing process all volatile elements in- cluding moisture pass off because the ore actually reaches the fusion point even though only momentarily. The net result less byproduct gas for fuel used around the steel mill, but far the merchant stack con- cerned, blast furnace gas em- barrassment plenty since the stoves consume only fraction the gases generated soft ore practice. For the latter, the saving furnace fuel cost when using sinter will net, while TABLE Typical Rail Freight Rates for Magnetite Sinter dack Mines Rate per Gr. Ton $2.58 Destination e om, Pa. Buffal for the the coke for suppli this conse gas have Alan Pa. upon milli take war. Adit sum the sin ore | 2.17 340 374 740 Sparrows 2.38 448-542 Magnetites for the steel plant the saving will the difference between the savings coke cost and the extra expenditure for auxiliary power fuel, normally supplied blast furnace gases. this connection, should noted that the higher blast temperatures for reducing sinter require _larger stoves for blast heating and consequently higher percentage gas for this purpose. For years some the Eastern mills have been operating magnetite sinter, notably the furnaces the Alan Wood Steel Corp. Swedeland, Pa. This company largely depended upon the Scrub Oak magnetite mine Dover, J., out which over million tons crude ore have been taken annually since the start the war. this supply has been added Adirondack sinter and during the past summer, Alan Wood began operating the mines the Ringwood Co. (in northern New Jersey) which had been dewatered and reopened with DPC funds after being abandoned since the last war. Expansion Began 1938 The importance the Adirondack ore bodies, hedge against the foreseeable depletion the great Minnesota ranges, wag first recog- nized large steel company when Republic Steel Corp. signed 25-year lease the Mineville and Port Henry TABLE Nominal Annual Capacities Ad- irondack Magnetite Mines Magnetite Crude Ore Mine Long Tons Tons Benson (J. Chateaugay 600,000 1,000,000 2,500,000 1,000,000 10,700,000 4,325,000 per cent Old Bed ore shipped lump. ST. LAWRENCE COUNTY HAMILTON COUNTY Highways showing the location the five active mining properties. Three ore bodies are being worked the Mineville-Port Henry area, two them through single shaft. properties the. Witherbee-Sherman Corp. This was 1938. year later Republic announced the signing similar lease the Lyon Mt. mine the Chateaugay Ore Iron Co., miles the northwest. Both prop- erties have been greatly expanded output since then. There every evidence that Republic the Adirondacks for keeps, including the step taken last July when the Cha- teaugay development was purchased outright from its parent, the Dela- ware Hudson Co. The had operated the property since 1903, al- though the mine has much older history. With went 140,000 acres timberland and unexplored mineral resources. Linney, who was gen- property for many years, now man- ager the Adirondack district Republic Steel Corp. His son, Robert J., runs the Port Henry division, and his son, William J., super- intendent the Chateaugay division. 1941, for entirely different reasons, National Lead Co., New York, and Hanna Co., Cleve- land, began the construction crush- ing and concentrating plants the sites old mines Sanford Lake (Tahawus) and Degrasse (Clifton Mine), respectively. See map. Adirondack Ores Being Reworked,” Frank Oliver, Iron Ace, March 1942, pp. 53-59. has been indicated previous ar- ticle’ National Lead was primarily in- terested exploiting domestic source ilmenite supply raw ma- terials its titanium division. will seen later, under pressure the WPB and with DPC funds, addi- tional equipment has since been in- stalled sinter the byproduct mag- netite concentrate. Hanna’s action reopening the old Clifton Mine tied directly with the WPB steel indus- try expansion program initiated 1941 and supplements its hematite properties Minnesota. These are primarily privately financed projects. 1942 surveys were begun the site the old Benson Mines, and later that year work was begun DPC financed concentration plant now operated the Jones Laugh- lin Ore Co. Table gives comparison the theoretical capacities crude ore mining and sinter output for these various properties. Table III presents while Table gives partial analy- sis the ores ard sinter produced each mine. general, the Adirondack magne- tites occur highly metamorphosed sedimentary rock consisting quartz, hornblende, garnet, silmanite and feld- spar, sometimes described feld- spathic gneiss. many the de- posits fair the mag- THE IRON AGE, January 25, = = = fuel the Te- ter- in- the for but ves ses the ost 1,300,000 425,000 500,000 300,000 aq netite solid enough and free enough from gangue make high grade direct shipping ore product. This particularly true Clifton Mine where the average content per cent. Guaranteed analysis Clifton lump ore given Table Mineville, the ores range from lean varieties, consisting mag- netite intermixed with quartz, feld- spar and hornblende, those made practically pure magnetite, the iron. The Chateaugay ores are lean—25 per cent Fe—but are num- bered among the finest the world because they run low phos- phorus and sulphur and are copper free. The MacIntyre ores differ from the rest that they average per cent TiO, and about per cent Fe, with about 0.2 per cent Some parts the ore body consist almost entirely magnetite and ilmenite. The leaner ores are mixed with gabbro—a term used designate dark colored, fine grained rock con- approximately equal amounts feldspar and ferromagnesium ma- terials. Republic's Expansion Although both the Republic Adiron- dack properties had been operated for years, until about 1941 the scale operations has been relatively small and the practice both mining and milling was obsolete compared with today’s standards. The Mine- ville deposits comprise two distinct ore bodies, the Harmony lying above the Old Bed vein and both dipping IRON AGE, January 25, 1945 approximately deg. For many years, each mined separately the Old Bed vein because the method attack, many five handlings were neces- sary bring the ore from the stopes the surface. After considerable study, Republic decided handle the ore from both veins through one central hoisting shaft that roughly parallels the upper vein. the bottom this shaft— about 3600 ft. down deg. slope— tunnel has been driven LEFT ATTERY churn drills work top bench, Clif- ton Mine. eh? RIGHT HERE the vein thickness relatively narrow, open cut operations are limited depth due danger falling rock. Below this point Clifton underground mining will employed. through rock the Old Bed ore body from which point new shaft be- ing sunk deg. slope. re- conditioned hoist has begn installed this level and the only rehandling required trolley train between the two cable hoists. The new main shaft, which straightens out some old wiggles, has been christened the “Don B.” honor Don Gillies, vice-president Republic Steel. now the largest single shaft mine the country. The new shaft went into operation September, 1942. Mining practice has been further improved the purchase up-to- date mining equipment, including wet drilling suppress the plus adequate ventilation. Through efficiency studies and consequent sion drilling, blasting and scraping practice, the manhours expended ton ore has been reduced almost one-third its former value. Repub. lic employs bonus system based tonnages produced. Although most the Old Bed now being hauled out through the new Don shaft, the original vertical shaft sunk the Port Henry Ore Co. tap this body has been put back into use for the purpose mining pillars the old workings, About 500,000 tons high grade ore has been recovered thus far, repre- senting about one-half one-third the potential. For its part producirg additional ore for the war effort Republic pre- sented plan the DPC for develop- ment the old Fisher Hill ore body, located within miles Mineville. Diamond drilling operation 1921 had indicated the deposit would yield least 40,000,000 long tons crude ore. The mine had last been operated 1893 and was flooded. got approval dewater the mine and order feed mill with annual capacity 2,500,000 long tons ore, three-track shaft was run down Bed ant mill, the old Henry Northe was Clevels Ohio. The comme althou early which cent forge: lower lake. ing could coal some here conv stacl tons over mad furn whe Cha iror ent | ‘ P ay. 4 » 4 ~y : rently 0) con tor th: 2 . the. 400 ft. where the slope deg. take advantage an. The two balanced hoists, holding long tons ore each, travel 2000 ft. the East, and the hoist has theoretical capacity 8000 tons day. For lack trained miners, however, Fisher Hill being cur- rently operated only about per capacity. The DPC setup this area also in- what probably the finest con- plant the Be- lack miners the Fisher mine, Republic processing Old Bed and Harmony ores through this mill, well output from the gov- ernment-owned mine. For the present, the old No. concentrator Port Henry idle. Incidentally, the Old Northern blast furnace Port Henry was torn down 1940. Sinter and lump ore being shipped from here Republic furnaces Cleveland, Youngstown and Warren, Ohio. Buffalo, Chateaugay History The Chateaugay development has commercial history going back 1873 although the ore body was known early 1823. which the early days ran per For years this ore, cent iron, served Catalan bloomery forges located Belmont, the lower (northern) end Chateaugay lake. Crude this process mak- ing wrought iron directly from ore was, showed that high-grade product could obtained largely due the the aralysis the blooms quality the ore. 1885 char- blast furnace was built Standish, few miles away where some forges had also been located. Later the Belmont forges were moved here and 1904 the blast furnace was converted coke. This was small stack with capacity about 500 tons day and after the took over 1903 specialized custom- made pig irons small lots. This furnace went out blast 1936 and when Republic leased the property 1939 the stack was torn down. Today Chateaugay low phos ore and sinter goes the Troy furnace and Buffalo made into merchant pig iron, Under Republic management, pres- ent-day operations Lyon Mt. are tremendous scale, 1918, for comparison, 114,140 gross tons crude ore were mined. 1937 out- put had been pushed 818,000 tons and 1943 1,323,000 tons. Output thus ten times greater than was the last war. TABLE Adirondack Crude Ore Reserve. Recovery Long Tons Ratio Indefinite 60,000,000 Old Bed Tolake level only. 24,000,000 long tons indicated inferred. The present shaft Lyon Mt. goes down 2350 ft. angle deg. the middle ore shoot that several thousand feet long the sur- face and has average mineable thickness about ft. per cent iron. The vein tapped from the shaft intervals varying from 150 300 ft. From the various levels the ore dropped down jaw crusher which reduces the ore 8-in. chunks before raised the sur- face. This the only mine the area where crushing done below surface. Sintering was begun 1921. Mag- netic concentration had been known and practiced here and Port Henry years before, but steady improve- ments were made. 1925, the sep- arator plant had been enlarged and modernized, but was only the last summer that wet magnetic sepa- ° ration entirely replaced dry separa- tion Chateaugay. This was done for several reasons: bring the plant the operating efficiency the newer installations the Adiron- dacks, suppress dust, raise the iron content the sinter and reduce the loss iron the tailings. Benson Mines The DPC has its second largest stake the other side the moun- tains, 100 miles west Lake Cham- plain Benson Mines, operated the Jones Laughlin Ore Co., sub- sidiary the Steel Corp. this connection should noted that there are several important dif- ferences between the various contracts entered into the DPC type lease, rental charges and means future acquisition the leasee. Some are long term; others are short term, factor which obviously influences the capital write-off charges. Leases are all royalty basis much per gross ton lump ore sinter shipped from the concentrator plant. Benson Mines the DPC has investment about million, and the lease runs for years. the option buy the plant, accumulated rental charges may offset the purchase price, but event shall the purchase price less than per cent the original DPC invest- ment. accumulated annual charge per cent interest the original ° powered either diesel engine electric motor are used load 35-ton trailer trucks Benson Mines. Churn drills are the upper bench. * : THE IRON AGE, January 25, 1945—53 per Mine the been 4 * - investment would also have met that time. Benson Mines old property. was first extensively worked for few years, beginning 1889, the Magnetic Iron Co., then was shut down. During the World War the Benson Mines Co. operated the prop- erty for few years. Altogether about 500,000 tons ore was removed. the field 1941, attempt was made explore the ore body which out- crops spots and other places lays under various thicknesses glacial overburden. The original plan was erect concentrating plant with annual capacity 400,000 long tons sinter. WPB request, this capacity was raised 1,000,000 tons. Since the got into operation last February, only half this output will attained 1944. About per cent the ore body land owned the Newton Falls Paper Mill, jointly owned Mc- Graw-Hill Publishing Co. and the Chilton Co., parent THE IRON AGE. The Ore Co. has leased acres the paper company land and has agreed mine this end the ore body proportionately. The New- ton Falls mill three miles north Benson Mines. With its own funds, 1941, Na- tional Lead Co. took over the old prop- erties the MacIntyre Iron Co. Sanford Lake and vicinity Essex County, primarily obtain the il- menite from what possibly the largest deposit titaniferous iron ore the country. Ilmenite, which TiO, associated with FeO, processed into titanium dioxide paint pigment; also opacifier whitener for rubber, leather fin- isher, inks, oil cloth and linoleum, TABLE Guaranteed Analysis Clifton Sinter and Lump Ore, Per Cent Elements Sinter Lump Ore Gain. paper and mineral welding electrode coatings, and for many other purposes. National Lead Co. financed the erec- tion mill buildings, roads and strip- ping operations, for the much more elaborate process separating il- menite from the magnetite well the country rock. Since July, 1942, until this past summer, magnetite concentrate was piled up—600,000 sistence and with DPC funds sin- tering plant could erected and put into operation. the interim, the principal use made this finely ground concentrate has been aggregate concrete block used for ship ballast. The block cheaper than lead and can readily handled bulk. Some mag- netite has been shipped blast fur- nace operators having excess sinter- ing capacity. The DPC sintering plant started experimentally last summer but will not make much dent into the stock pile magnetite concentrate until minor part the sintering plant equipment straightened out. Thus far only small shipments sin- TABLE Partial Analysis Adirondack Magnetite Ores and Sinter, Per Cent ORE BODY 54—THE IRON AGE, January 25, 1945 CRUDE ORE ter have been made. Rated capacity the sintering plant 1800 long tons day. Big Ore Reserves National Lead working only one the titaniferous magnetites this area. Aside from the original work- ings known the Mill Pond, there are deposits rich ore (more than per cent iron) nearb