The Iron Age 1945-02-01: Vol 155 Iss 5

— Editorial and Advertising East 42nd St., New York 17, N.Y. AGE Vol. 155, No. February 1945 VAN DEVENTER President and Editorial Director BAUR Vice-President General Manager LEONARD Assistant General Manager HAYES Advertising Manager JOHNSON, Manager Reader Service and Market Research BAUR, Production Manager CLEARY, Sales Promotion Manager Regional Business Managers New York New York Technical Articles KAY Magnesium Alloy Metallography...................... | | Executive Offices nts and Chestnut and Sts. Philadelphia 39, Pa., U.S.A. Features BAUR Vice-President Personals and Obituaries WILLIAM BARBER, Treasurer Member Bureau Circulation and Markets OSTS Machine Tool Market Developments................... 125 Non-Ferrous Metals News and Prices............. Member, Associated Business Papers and Iron and Steel Scrap News and 130-131 writing Comparison Prices Week and 132 Finished Iron and Steel, Steel Prices................ 134 Warehouse, Semi-Finished, Tool Steel 136-137 Stainless Steel and Ferroalloy Prices................ 142-143 ° | | | | NC. Ave. Fabrication parts, such this Gear Case, typifies the kind work that combines moke the thousands tons weld- ments Mahon called produce. The attention all industry has been focused WELDED STEEL PLATE CONSTRUCTION the fabrica- tion implements condition that certain carry over into the manufacture peacetime parts and products. The advantages are manifold. WELDED STEEL PLATE stronger and lighter. requires less machining and finishing. eliminates pattern expense and reduces scrap. non-porous. presents smoother, finer, THE 40—THE IRON AGE, February 1945 appearance and, nearly all instances, parts products can produced quicker time—at attractive cost. Supplementing the extensive production facilities able Mahon staff experienced design gineers. These men are prepared give you and complete information adapting your produd the advantages WELDED STEEL PLATE STRUCTION. They will also assist you its that should required. ‘ * ‘ A : | Fabricators Machine Bases and Frames and Many Steel Plate Feb. 1945 VAN DEVENTER President and Director BAUR Vice-President and General Editerial Commercial CAMPBELL Editors WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Editorial Assistants SCHIEN VAN CAMP MUNZER O'CONNOR MILLER HANSEN DAVIS News and Technical LLOYD Pittsburgh 428 Park POST Chicago 1134 DONALD BROWNE EUGENE HARDY Washington National Press LLOYD Cleveland 1016 Guardian Bidg. BRAMS Detroit 2310 Woodward Ave: OSGOOD MURDOCK San Francisco 1355 Morket St. Editorial ROBERT Cincinnati DEAN Buffalo Boston HUGH SHARP Milwaukee SANDERSON. Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham St. JAMES DOUGLAS Seattle ROY EDMONDS Trading Ace for Two Spot HERE very human and natural state mind that call “hero worship.” has come down through the ages psychological reaction the average man’s acknowledged need for leadership. Thus quite normal and perhaps altogether good consider that the man who elected the presidency our country because Divine Providence possessed those great impartial qualities that will cause him act, matters state, without regard any consid- erations whatever other than those the best interests the public large. must, therefore, disillusioning many, many millions learn, have recently, that our beliefs this respect are not merely illusions but delusions. Tammany chieftain could act with more crass and utter disregard rewarding ward heeler for votes delivered than has the President the United States kicking Jesse Jones out office make place for Henry Wallace. This reflection the Honorable Mr. Wallace, who far know, has been forthright expressing his views and has never carried water both shoulders. does not like business and has said so. doesn’t admire the profit system and has said so. likes the most radical elements our labor empire and has said so. Every man entitled his opinions and his likes and dislikes, Jesse Jones Democrat. Like the vanishing Indians, perhaps one the last that tribe. such respected and admired much Republicans those who voted the opposite ticket. Jones knows his business because business man. built his own business and did not inherit one that was incapable running. man whom the average American can entrust his bank ac- count and pocket book, knowing that the money will regarded sacred trust and not shoveled down the sewer. The crime for which was beheaded was that for years played square with the great funds entrusted him. Forty billion indeed great sum money. enough make break the future every man and woman America. The ordinary office Secretary Commerce one that under proper supervision has been useful American business. But business can take leave and with Mr. Wallace the head the latter what will undoubtedly do, for the average American businessman takes truck crystal-ball gazing astrology formulating his plans. willing leave that Rasputin the astrological expert who acts consultant Hitler. far business and industry are concerned, the title Secretary Commerce does not “cut much ice” but the control billion dollars taxpayers’ money does. Edgar Bergen very wisely restricts his Charley McCarthy ex- penditure cents week, knowing his qualifications and peculiari- ties. indeed difficult conceive Charley McCarthy sitting the lap Sidney Hillman with practically unlimited funds scatter his friends. That would something! doubt Henry Agard deserves something for his allegiance the New Deal and for graciously accepting turn down for the vice- presidency. But the control billion dollars too big com- mensurate with services rendered any party. And indeed, that would minor part the cost. The major part would complete dis- illusionment the integrity the present administration. ESTABLISHED | | { arts Inland Steel anywhere among America’s fighting men the South Seas and you will find steel from Inland—sometimes working for Victory permanent base—at other times plowing the South Seas, car- rying men and supplies many types fighting, carrier, and landing vessels. the picture shown above LST, with bow doors swung wide, emitting flow vital supplies for Rendova Island the central Solomons. Aiding this work craw- * Official Navy Photograph courtesy Bay City Shovels, Inc. the South Seas ler-type crane. the foreground are personnel landing craft. Thousands upon thousands tons Inland plates, sheets, and structural shapes have gone into building cranes and craft these types. Today, every day since the attack Pearl Harbor, Inland mills and Inland men are engaged full time making steel for America war. Bars Floor Plate Piling Plates Rail Reinforcing Bars Sheets Strip Structurals Tin Plate Track Accessories INLAND STEEL COMPANY Sales Offices: Cincinnati Detroit Kansas City Milwaukee New Yerk St. Paul 1a News Front 30, 1945 The future possibilities large-scale steel production the West Coast Geneva and/or Fontana are bogged down welter conflicting data that Which has great stake both, has Arthur McKee Co. making new Fontana and Freyn Engineering Co. making similar survey Geneva. The miser Co. has Brassert making duplicate survey its own situation. These reports will cover raw materials, plant facilities, freight rates, possibilities, etc., and will completed four six months. Whether the situation will clarified doubtful. Meanwhile: Fortune magazine will soon out with elaborate pronouncement its own, with the conclusion that Fontana was built more quickly and effi- whereas Geneva has better basic setup. This conclusion apparently one. American Bridge Co. will likely make equipment after the war, Caterpillar Tractor Co. distributing the equipment. Caterpillar has its distributorship with LeTourneau. Possibly the American Car Foundry Will assemble tractors for the Bridge combination. Shipbuilding the West Coast being curtailed, preference being given work. Bethlehem yards will add, and fact, are now adding additional handle this repair work. Periodic renegotiation contracts and the closer pricing policy the Navy have effected price reductions that are obtaining per cent moré war for each dollar expended than was obtained early 1942. For example: The Navy now paying about one million dollars less per royer than did the beginning 1942; the price one type landing raft has been reduced from $21,000 $17,000; the price one type fighter has been reduced from starting price $66,000 volume production rice $32,000 and one type bomber plane from $118,000 $58,000. Industrialization the South American Republics will result heavy pur- railroad equipment this country, Kraehn, assistant the resident Baldwin Locomotive Works, predicts after surveying present and equipment needs the spot. The need for locomotives described acute although the largest potential arket, Argentina, will get aid. Enlarged major ammunition programs have increased requirements for screw hine products per cent over the demand existing January last year. thousand American made machine tools, together with ttachments and spare parts have been sold the United Kingdom for $31,500,000 quite per cent the original cost $166,000,000. The amount paid the British based depreciation due the intensive the tools under wartime conditions and represents agreed estimate the alue they will have after they are longer required for the war effort. Reworking the Adirondack magnetite mines will probably not die out when the Recent operations have proved that high grade product can supplied blast furnace. The vast ore resources are yet hardly scratched and when these mines and can operated full capacity, when manpower problems disappear, will brought competitive position with those Lake Superior ores the blast furnace. — = a > a tables and charts shown below and the following two pages, are revisions similar data that appeared THE IRON AGE, Aug. 28, and have been.prepared Rolf Sartorius metal- lurgist, National Lock Washer Co., Newark, great deal technical and commercial informa- tion regarding the principal tool steels has been gathered together rather limited space for quick reference. Mr. Sartorius has grouped his steels according type numbers, following the matched tool steel system developed the Car- penter Steel Co. and exemplified diamond diagram (opposite), which reproduced Tool Steel Suppliers Carpenter Steel Co. No. Special Solar Steel Co. Omega Sanderson Belle Crucible Steel Co. Extra Silicon No. Ackerlind Steel Co. White Label Silman Vanadium-Alloys Steel Co. Colonial No. Mosil Heller Bros. Co. Blue Label Latrobe Elec. Co. Extra Carbon Damascus No. 602 Allegheny Ludium Steel Corp. Pompton Extra No. 609 Jessop Steel Co. Lion Extra Magic Chisel Whelco Wheelock, Lovejoy Co. Standard Joseph Ryerson Son Universal-Cyclops Steel Corp. Cyclops Extra Venango Vulcan Crucible Co. Extra 4870 Firth Sterling Steel Co. Special Chimo Braeburn Alloy Steel Corp. Extra Triton Midvale Steel Co. Duredge Columbia Tool Steel Co. Extra Milne Co. Red Label MSM Simonds Saw Steel Co. Blue Label Havoc Henry Disston Extra D-29 Timken Roller Bearing Co. Graph-Sil Graph-Al with permission that company. The generd designations grades are Carpenter's also, the numbered designations are those used the National Lock Washer Co. These tables answer many questions the selection tool steels. The large table the trade names and manufacturers the nine main classifications tool steels, and the tables summarize the application, approximate treatment, and chemical composition each type not strictly within the type analyses. addition, for No. grade, which ordinary high speed and for No. which tungsten hot-work steel, GRADES K-W Stentor Ham Tool Room Lehigh Finishing Oil Hardening Bethalloy Tool Crucible Ketos Champion Double Special Champaloy Green Label Violet Label Colonial No. Colonial No. Non-Shrinkable Nikro Cro Gray Label Mangano Special Saratoga Deward Hur Extra Tough Rapid Finish Truform No. Whelco Whelco Finishing Oil Hardening Ry-Alloy Saturn Wando Ultradie Regal Non-Shrinkable Triple Kiski Superior Dian Finishing Constant Double Special EXL-Die Super Fast Finishing Amcoh Double Teenax No. Mansil Celero Oil Hardening Nicroman 812 Dit Graph-Tong ‘ j = | | j — ba also, but the egarding resent; the nine bre also given, although this material not ate ach addition, steel, steel Hur Ultradie Triple Superior Bran Super (7") and chromium-tungsten-molybdenum hot molybdenum alloy steels are given Nos. and because restrictions placed tungsten alloy steels the war program. More ecent easing alloy restrictions has permitted sage tungsten-molybdenum type high speed Greater wear resistance ork steel (8"). Alternate analyses for No. grade rimarily tungsten steel. Red- Hard Red-Tough published serially THE IRON AGE ond available booklet form. wear resistance Greate: toughness Excelo No. Chisel Steel Atha Pneu Hot Die Steel Orange Label X.L. Chisel Seminole Hard Top Notch Alco Q.A. J.S. Punch and Chisel Buster Commando No. Keystone Star Zenith Star-Max. Speed Star D.Y.O. No. 883 Special H.M. No. No. No. 445 High Speed High Speed High Speed Hot Work Hot Work Hot Work Rex TMO Crescent Hot Work Rex Rex Rex M-2 Peerless No. LaBelle Chro-Mow Superior 8-N-2 6-6-2 Marvel Choice No. Hotform Red Label Die Peerless Brown Label Electrite Electrite Special Electrite No. Tatmo Double Six Select L.P.D. Atlas LXX DBL-2 Atlas Alloy Potomac B-MC Supremus Mogul Mustang Dica J.J. Hot Work Dica Whelco High Speed Hot Die No. B-6 Mo-Tung Mo-Tung 652 B-44 Ajax No. Thermold “B” Wolfram Vul-Mo T-M-5 Calo Ferro 4-H.W. T.C.M. Blue Chip Star-Mo Forging Die C.Y.W. H.W.D No. Vinco Mo-Cut Braemow T-Alloy Hot Die No. Pressurdie No. Bolt Die Special Two Star Nut Piercer Bolt Die Regular tmodie Clarite Molite Formite Phoenix Firedie High 3074 Chrome AMC Hot Work Hot Work Chrome Red Streak Molva-T D.N.V. Hot Die Kutkwik Di-Mol 6-N-6 Eltun H.R.W. Alloy Chisel O1l-Tough Water -Tough Ham Lehigh Tool Viet Cro | mM | ow BA 49 Ceeysung 104 S18Ajeuy edAL is UW 2 00°6 SISATWNV sjoo, Sujysjusng Suywis04 seyound shnig “Bujuepsey ui “ON 46—THE IRON AGE, February 1945 Biquinjog Biquinjog _——— 8910 440M 10H S18Ajeuy edAL 2 OR Guyws0 4 8 d 6 s6 6 ul THE IRON AGE, February 1945—47 NDER the stimulus large production during recent years many electrical devices have been developed for the accurate control spot welding machines. was obvious that some means con- trolling electrode tip size was es- sential maintain consistent welding results. Based experimental work first carried out the spot welding light alloys, was found that due the high conductivity the ma- terial used the electrode tip diameter SIMMIE Pressed Steel Co. Ltd. Cowley, Oxford, England ° ° completed deals with this subject. The results comparative tests carried out the same time.on two standard electrode materials are also available. The results the investigation the spot welding S.W.G. steel sheet have been published Journal the Institution tion Engineers (Great Britain) December, 1942. For comparative purposes some the test results tained are included this report. The investigation included the ing 20, and gage mild steel sheet. Auto body sheet was used pated the and gage tests and low should controlled within certain limits maintain the high degree weld consistency required. infor- mation was available, however, re- tion with the welding mild steel sheet and the experimental work now £ troll erati welds per min 1000 2000 3000 4000 5000 Water per min. Number welds water with varying rates flow. tests tip wear 2.0 ing the angle the 1.6 Welding pressure— Water cooling— using tip 4—Resistance measurements IG. Form taken two thick- electrode used for nesses sheet held 0.2 all tests and between the rial). 48—THE IRON AGE, February 1945 Electrode pressure, bon | obtai | | | { { | Steel mild the in) ort. steel single pickled material for the tests. The electrode materials used were: (a) copper containing 0.9 per cent cadmium and (b) copper containing 0.6 0.7 per cent chromium. The chromium alloy has higher softening temperature than cadmium copper and less tip wear was antici- pated. was therefore decided obtain comparison with standard material such cadmium copper. The work was carried out 250 experimental spot welding ma- installed the welding labora- the Pressed Steel Co. This machine fully automatic, both the pressure and welding cycle being con- trolled thyratron control panels op- erating conjunction with chanical timers. Preliminary Experimental Work Water cooling: series tests were carried out determine the minimum rate flow cooling water through the electrodes using standard which the water was circulated within in. the tip surface. The temperature rise the water was recorded for vari- ous rates flow. The results when using welding speed welds per are shown They indi- that efficient cooling obtained with rate flow gal. per min. Form electrode tip: Standard tonical shaped tips were used for series tests tip shape. was found that reducing the angle the base the cone the tip life could considerably increased. The re- sults the tests are illustrated graphically Fig. while the form electrode used for all tests shown Fig. The initial tip diameter used was in. for and gage material and 11/32 in. for the gage Electrode pressure: Resistance measurements were taken two thicknesses sheet held between the various pressures, the test pieces being removed before each test. The tip diameters used similar those used the welding test. The resistance obtained measuring the volt- age drop across the electrode tips when connected low voltage d.c. The results obtained are 5000 Careful observation changes the form and size elec- trode tips due wear helps attain high degree welding consistency, according elaborate experimental work carried out British plant. The data were supplied through the courtesy Metal Industries.” 0.25 1000 2000 3000 4000 5000 Number welds Fig. 5—Spot welding tests for 20-gage mild steel sheets. Welding Current 9220 amp. Speed welding welds/min. Welding time cycles Water cooling gal./min./electrode Welding pressure 10,000 in. Nominal tip diameter Average Weld No. Contact Area Tip Diameter Tip Area Strength per Spot Welds Sq. In. In. Sq. Lb. Cadmium Copper Electrode 0.0491 0.0533 0.0574 0.0574 0.0614 0.0614 0.0614 0.0660 0.0660 0.0706 0.0706 0.0706 MON o 0.0594 THE IRON AGE, February 1945—49 ° ° 1100 250 0.0400 1320 500 0.0425 1150 1000 0.0423 1270 1500 0.0450 1210 2000 0.0450 1310 2500 0.0450 1260 3000 0.0475 1320 0.0500 1220 4000 0.0525 1180 4500 0.0525 1300 5000 0.0550 1320 Chromium Copper Electrode 0.0375 0.0491 1190 250 0.0375 0.0533 1190 500 0.0375 0.0533 1370 1000 0375 0.0574 1280 1500 0.0574 1280 2000 0.0425 0.0574 1120 2500 0.0425 0.0574 1280 3000 0.0425 0.0574 1220 3500 0.0425 0.0594 1120 4000 0.0425 0.0594 1280 4500 0.0425 0.275 0.0594 1090 5000 0.0425 0.28 1100 900 meter Sa) Tip diameter, in. Percentage increase tip dia 4000 6000 Number welds 8000 10,000 Fig. welding tests for 16-gage mild steel sheets. Welding current Welding time Welding pressure No. Contact Area Welds Sq. In. 0.0375 0.0375 0.0400 0.0400 0.0450 0.0450 Speed welding Water cooling Nominal tip diameter Tip Diameter In. Tip Area Sq. In. Cadmium Copper Electrode 0.0491 0.0531 0.0551 0.0594 0.0638 0.0661 0.0683 0.0707 0.0707 0.0707 0.0707 0.0707 0.0707 0.0731 0.0731 0.0731 0.0755 Chromium Copper Electrode 0.0375 0.0375 0.0400 0.0400 0.0425 0.0425 0.0425 0.0450 0.0450 0.0450 0.0450 0.0450 0.0450 0.0450 0.0450 0.0450 0.0450 50—THE IRON AGE, February 1945 0.0491 0.0511 0.0531 0.0531 0.0551 0.0551 0.0551 0.0573 0.0573 0.0573 0.0594 0.0594 0.0616 0.0616 0.0616 0.0616 0.0616 welds/min. gal./min./electrode Average Weld Spot Microscopic examination the sheet surfaces showed that the sheet had rougher surface than the sheet and the results cate that the sheet surface the con. trolling factor resistance values the thinner gages material. The welding pressure used the actual welding tests was 10,000 Ib. per sq. in, electrode tip area and the broken lines the graph indicate that the resistance approaching constant value under these conditions. Welding current and time: possible use large selection current and welding time settings but these investigations the object. was use high welding currents and short welding times. The settings se- lected were the maximum values which sparking during welding was eliminated. Speed welding: welding speed welds per min. was used all tests. This average speed welding tinuous production line. Description Tests adopted for all thicknesses ma- terial. The electrodes were set the machine and preliminary test pieces were welded and tested tensile testing machine. The contact area and tip diameter were recorded and the test run started up. se- lected intervals the run was stopped and three test specimens prepared. These consisted welding two strips the material under test in. long was used and one spot weld was made each specimen. The average break- ing load for the three specimens was recorded. the same time the tip diameter and tip contact area were also recorded. The test runs were continued for 10,000 welds the and gage material. the S.W.G. material test run 40,000 welds was made using 3/16 in. elec- trode tip diameter but for compara- tive purposes the results test run 5000 welds using in. diameter electrode tips are given. The test results for cadmium cop- per and chromium copper electrodes are given Figs. and and the tabular matter. clearly illustrated that long- tip life can obtained when using chromium copper. further important conclusion that the contact area all tests in- creases only very small amount. This particularly noticeable the sheet thickness increased. The clec- trode tip area does not appear related the actual contact The object running the tests for 10,000 weld weld tes electro the tend the surfac contac tip face produ spot the when have (reas reduc = 040 0.36 | 034 taine 500 0.265 1920 taine 1000 0.275 1880 elect 2500 0.0475 0.295 1890 3000 0.0475 0.300 1920 3500 0.0475 0.300 1910 4000 0.0475 0.300 1920 4500 0.0475 0.300 1900 6000 0.0475 0.300 1960 7000 0.0475 0.305 1920 8000 0.0475 0.305 1890 9000 0.0475 0.305 1920 10000 0.0475 0.310 1900 tons was 250 0.255 1860 1000 1500 0.265 1880 2000 0.265 1870 the 2500 0.265 1840 3000 0.270 1860 3500 0.270 1850 4000 0.270 1880 4500 0.275 1910 5000 0.275 1870 6000 0.280 1870 act 7000 0.280 1860 8000 0.280 1880 9000 0.280 1850 10000 0.280 1870 Sheet welds was obtain elec- tip size which unsatisfactory the strengths were obtained. was indi- surprising find that the strength was maintained after test run was completed. The was observed when welding the in, tips sunk into the sheets due roken the softening the steel there was the tendency for wear occur round circumference the tip, leaving area slightly “proud” the tip ~ tip diameter Mm Tip diameter, in. round the circumference the automatically maintains this sur- 4000 6000 8000 and area almost constant value. Number welds se- has been observed high speed lines thdt satisfactory mild steel sheet when electrode speed have increased 100 per cent all original tip diameter. These re- elding however have only been obtained the parts welded are Fig. 7—Spot welding tests for 10-gage mild steel sheet. When badly fitting parts spot welded large in- 13,600 amp. Speed welding welds/min. was the pressure per square inch Welding pressure Nominal tip diameter ma- tip area and faulty welds are ob- making use these experi- No. Contact Area Tip Diameter Strength per Spot results should noted that Welds Sq. In. In. Sq. In. Lb. ontact spot welding was carried out un- se- Conclusions these tests are briefly opped listed follows: Cadmium Copper Electrode 0.0525 0.0928 pared. The amount tip wear ob- 0.0555 0.1134 strips depends upon the shape the 0.0555 0.1195 long tip. truncated cone hav- 0.0555 Electrode tip wear can re- 0.1386 was duced using chromium copper. tip The increase tip area not were the increase actual con- were tact area. the When similar experimental work 40,000 light alloys the weld strength was 0.485 elec- reduced after 2000 welds and the growth the tip diameter test therefore strictly controlled. This in. achieved limiting the number Chromium Copper Electrode cop- from the experimental work now 0.36 trodes that the requirements 0.37 and tip maintenance governing the welding light alloys are not ap- 0.38 long- the spot welding mild 0.385 Much greater latitude per- 0.390 for the welding the latter. sion These tests were carried out re- 0.400 sts in- «tance type d.c. operated spot welder. 0.405 mount. Acknowledgments: The author clec- the Pressed Steel Co. 0.43 0.1452 ltd. and the Institution Produc- area Engineers for placing this data sts for disposal. THE IRON AGE, February pper 5300 5400 5000 5150 5500 5550 5550 5400 0.1521 5450 0.1591 5550 0.1662 5450 0.1698 5400 0.1735 5300 0.1809 5500 0.1847 5450 5510 5200 5520 5500 5650 5500 5400 5450 5600 5400 5000 5550 5450 5500 5300 ITH variations, the process beneficiating Ad- irondack magnetites the same throughout the mountains and will described present both economic and engineering fac- Essentially there are six stages the ore processing: crushing and *For highly detailed description the mining operations, mill equipment, flow sheets and historical data these six Adirondack magnetite and mills, the reader referred the No- vember, 1943 Adirondack iron mining issue “Mining and Metallurgy,” pub- lication the American Metallurgical Engineers, New rough separation, milling fine grinding, wet magnetic separation, dewatering the concentrate, mixing with small percentage anthracite, and finally sintering. The basic economic problem magnetic separation maintain the tailing loss minimum and the same time strive for high per- centage iron the concentrate possible. proper control the magnetic separators also possible throw out undesirable elements like phosphorus some degree. All these factors are tied with the structure the ore, the minerals with which associated and the method mining. For ex- ample, drilling with drills under- ground confined space results more fragmented rock and there- fore simplifies the crushing problem the deep mine plants. The newly reopened mines—Ben- son, Clifton MacIntyre—are all be- ing worked today open pit mining operations and the quarrying pattern similar all three. National Lead has opened benches Sanford Hill, each ft. high, and has exposed practically the entire outcrop ore. Benson and Clifton ft. benches levels are used. The usual method blasting out ore bearing rock sink in. holes ft. centers and ft. from the face the bench. This done with fishtail bit churn drills which are operated like well driller. takes about hr. drill the first ft. and hr. the next ft. because time lost retract- ing the tools and pulling out the finely ground sludge. About 400 500 dynamite lowered down each hole and the entire face blasted. Supple- menting the churn drills are power fed, pneumatic wagon drills and hand held drills. Power shovels, operated electrically diesels, pick the broken rock and load into trucks for hauling the crusher. Pieces too big handle with the dipper are drilled with com- pressed air and blasted. Maintenance the big item this crushing plant and the concentra- tor mill. pure luck all the power shovels and trucks are op- eration once. Even major repairs must made the premises and often right the pit the case the big shovels. the mill there are huge piles tailing rock Lyon Mt. give evidence the years continuous operation the present Chateaugay Division Republic Steel Corp. Ze | & bottlenecks galore caused ical breakdowns—a motor burns out the primary crusher, in. rub- ber belt begins tear apart the roller bearings get “shot” the sin- tering machine pallet conveyors. Crushing Practice The crushing problem varies with the mining method and type ore. Benson Mine the largest crusher the mountains. Into this huge Cully gyratory crusher (Allis-Chal- mers), which weighs 670,000 ore bearing rock ft. thick and much longer dumped directly from 35-ton trailer trucks. The product from this crusher dropped gravity two in. fine reduction crushers. This equipment sunk ft. pit, the dumping level which 125 ft. below surface. present, ore trucked down the crusher. From 125 250 ft. below datum line (limit open pit quarry- ing) the rock will the crusher house. Most other Adirondack use jaw crushers for the primary reduc- tion. Clifton the ore tends break into cubes and hence the first reduction the crude ore can brought down in. finer, without difficulty. After screening, all material except the in. under- size sent over dry magnet pulley cobbers separate the lump ore, which assays about per cent iron, 8.19 per cent silica, 0.300 per cent sulphur, and 0.124 per cent phos- phorus. Lump ore constitutes about per cent the erude ore output Clifton. Rejects from the cobbers and undersize from the primary IRON AGE, February 1945 | 4 cru: sett mat not Bef : sun are pro thr use fro ore cru hig cob crt scr ° ° | with usher Chal- ore and from the below use the finer, ening, pulley ore, iron, phos- about imary crusher are then sent through in, gyratory crusher having in. setting, after which reduced in. two reduction crushers be- fore being wet milled. National Lead, also, has been found that crushing three stages instead the original two, overall output materially increased and machinery maintenance reduced not calling upon the primary jaw crusher reduce the ore too finely. Before being sent the short head bowl cone crushers (which operate closed with double deck screens), the secondary crushed ma- terial conveyed belt over dry cobbers, installed this past summer. Rejects from the cobbers are discarded, instead being re- processed Clifton where cobbing done extract lump ore. About per cent the country rock thrown out this point. Magnetic cobbers are now also use Mineville separate lump ore from the Old Bed primary crushed ore which comes through the jaw crusher in. size and under. About per cent this crude ore high enough magnetic iron pro- duce suitable lump ore for open hearth use. Rejects from the lump cobbers are conveyed the secondary crushing plant. Here the material carried closed circuit through battery double deck vibrating screens, cone crushers and double pulley type magnetic cobbers, from which rock discarded waste. Ore in. and under sent over the tod mills the new DPC concen- ° ° ° FRANK OLIVER ° ° the second and concluding part the article, the various methods beneficiating these ores are described. fine grinding enables concentrate containing per cent iron obtained magnetic separation. The product then sintered. trating plant nearer Port Henry. similar arrangement used Lyon Mt. except that the primary crushing done below surface and the ore brought 8-in. lumps and under. the headshaft. the material screened and the coarse particles sent through jaw crusher. Material passing in. mesh screen but retained in. mesh cobbed magnetically and rock containing less than per cent iron discarded. The magnetite bearing material finally reduced in. and under before conveyed the concentrator plant for wet milling. Thus seen that the time the ore reaches the second stage and finer, although least one plant, the product the last gyratory reducer nearer in. than in. Degrees fineness wet grinding vary with the type ore and the new DPC concentrator and sin- tering plant operated Republic near Mineville arranged hillside take advantage gravity han- dling crushed ore end product sought. Development National Lead, for instance, where the primary problem separation the ilmenite from the magnetite, grinding carried further than the other mills and even finer grinding has been suggested effect better separation. is, the material will all pass through mesh screen (coarse particles are re- turned the rod mill closed cir- cuit) and high percentage (33) will pass 100 mesh screen. Most other mines mill mesh maximum particle size. Since milling and magnetic separa- tion hand hand, the equipment for this purpose generally, under one roof. Every Adirondack concen- trating plant now employing wet magnetic separation, although some the older plants changed over from dry wet practice only the past summer. Two types wet separators ars use, the Crockett and the Lin- ney types, each made Dings Mag-. netic Separator Co. both designs, the finely ground ore suspended rapidly moving water flushed flowed against wide rubber covered canvas belt which passes under battery powerful d.c. electromag- nets. THE IRON AGE, February 1945—53 | } chan- out Tub- the Sin- ‘ The Crockett type machines are development Robert Crockett, for many years general superintendent the Scrub Oak mines Alan Wood Steel Co. where New Jersey mag- netites are concentrated. The Linney units are modification worked out Robert Linney, general superin- tendent, Port Henry Division, Re- public Steel Corp. The Linney unit differs from the Crockett that the tilt the belt steeper (about deg. vs. deg.) and the ore laden water flushed against the belt with hydrostatic head from distributor box instead flowing along the*un- derside the belt pan. both machines the magnets, encased stainless steel housing, consist series poles alternate polarity which tend roll over the magnetite particles held against the belt. Dragging the ore under water from pole pole severely agitates the particles, allowing the non-magnetic particles drop into the middlings and tailings sections. The concentrate given final flush under the last several poles and then discharged vibrating screen. the Linney units, the magnetic particles are sprayed with jets mill water, thus rolling them over and effecting what separation. Magnetic Separators separation done two stages, the second battery separa- tors being termed the finishers. The new magnetic concentrator near Mineville processes the crushed ore first through set nine in. wide roughers and the concentrate drops gravity vibrating screens. Material passed the screens goes directly the finishing separators, while the coarse particles rejected the screens are reduced 8x12 ft. rod mills, one serving battery three rough separators. Coarse particles from the mills are again screened and the rejected ore recirculated through the mills. Fines battery finishers third and lowest level and the end product dewatered six rotary vacuum filters from which the damp ore goes silos the sintering plant. The arrangement Benson Mines differs the extent that product from the fine cone crushers fed first through three ft. rod then elevated bucket chain battery nine magnetic rough- ers the upper deck. Oversize screened concentrates the Crocketts reduced two 8x8 ft. ball mills before going the finish- ers. Dewatering done dewater- 54—THE IRON AGE, February 1945 ATTERY Linney type wet magnetic Republic's new DPC plant near Mineville. ing cones, the sludge from which then put through rotary vacuum filters. Clifton, product from the ter- tiary cone crushers single ft. ball mill and then screened. Oversize particles are recirculated through the ball mill while 12-mesh undersize goes three Crockett magnetic separators which combine rough and finish concentration taking off three classifications—con- centrate, middlings and tailings, the last named which goes waste. The middlings are recirculated through the ball mill. Concentrate partially dewatered cone, the sludge from which goes rotary vacuum filter and thence the sinter plant. Lyon Mt., product from the last cone crusher goes rod mill, and until the last summer, the coarse material (minus mesh and plus 100 mesh) was separated dry. The minus 100 mesh material was con- centrated wet machines. Now the entire screened product the rod mills eventually all goes two bat- teries rough and finishing wet TABLE Sanford Hill Ore Production July, 1944 Magnetite Tailing separators, the newest being the Lin- ney type. National Lead has different prob- lem since the primary end product ilmenite and the secondary product magnetite sinter. The separation these two products difficult since ilmenite has much lower magnetic permeability than magnetite, which about per cent magnetic pure iron. the wet mill four ft. rod mills grind minus in. ore mesh. Screen undersize split Crockett separators which pro- duce magnetite, well middlings, tailings and slimes overflow. The mag- netite concentrate dewatered about per cent moisture four rake dewaterers and then delivered stock pile. This material analyzes around per cent and from 9.5 10.0 per cent Since the plant was operation almost two years before sintering was started, 600,000 tons magnetite concentrate has been piled backlog for the sintering plant. All the remain- ing material passed over battery wet concentrating tables jigs. Tailings first eight hydraulic sizers sand spigots which discharge classified product sand tables. Crockett separators and the sizers eventually slime tables after being deslimed hydroseparators. Each concentrating table produces ilmenite concentrate the end the table, middling which circulated through the Crocketts and tailing which sent waste Lake Sanford. The tables are op- TiO, all which eventually dewatered rakes and a Lin- prob- luct roduct ion since gnetic which tic 6x12 ore split pro- llings, mag- four ivered alyzes from the two ntrate for attery jigs. tables. the sizers after oduces end and ste cent and dried stationary steam coil dry- Wetherill dry magnetic separators, having four coils and eight take- cross belts. The first two belts, under low intensity mag- nets remove residual magnetite and the next five belts recover the ilmenite while the last belt product mid- Final ilmenite concentrate averages about per cent All the magnetite from the Wetherills with part the middling returned the wet mill. Because the slimes and tailings as- grade lump ore being ob- tained the Old Bed mine Mine- ville mining pillars old mined out areas. This one 100 ft. high and ft. -in diameter. and from 14% per cent iron, plans are being considered reprocess these tailings flotation methods. About 600,000 tons tailings form Lake Sanford. The fact that there relatively high iron content the high specific gravity gangue materials which contaminate the table concentrate and are there- fore nearly magnetic the il- adds the problem loss both ilmenite and iron the tail- ings. (See Table VI). From the start the milling operation, the slime load has been greater than originally anticipated and the slime tables have been overloaded great extent. The recent installation cobbers after the tertiary rock crushers has relieved this problem some extent inasmuch about per cent gangue eliminated this point. Recovery mill water well precipitation tailing fines prob- lem Benson Mines and the Port Henry area. both places Dorr thickeners have been installed serve both purposes. Outside the DPC con- centrator near Mineville 200 ft. diameter thickener the open from which three-quarters the water tailings recovered. The sludge raked from the thickener dumped small collecting basin and none the solids. enters streams which feed Port Henry’s water sup- ply. Benson Mines, two Dorr thickeners, ft. diameter, are housed under roof. The sludge pumped overhead pipe line tailing dump. Sintering Practice all but the DPC sintering plant National Lead, sintering done continuous pallet type Dwight-Lloyd machines. The two Dwight-Lloyd ma- chines installed near Mineville are but two five that Republic Steel Corp. has put under DPC auspices the WPB sponsored expanded steel capacity program. The other three are Warren and Youngstown, Ohio, and Spaulding, Ala. The two in. machines Mineville have annual capacity 382,000 net tons, 1500 gross tons per hr. There one machine similar size that has been operation for some years Lyon Mt. Benson Mines there are two in. machines somewhat greater length, which allows them operated higher conveyor travel. Hanna Ore Co. has one in. machine Clifton Mine. Throughout the Adirondacks, the fuel used for sintering anthracite culm, for many years stock piled waste product from the coal cleaners eastern Pennsylvania anthracite mines. Delivered Adirondack sin- tering plants, this fuel worth about ton, the bulk which freight charges. About per cent the culm mixed with the magnetite concentrate pug mill just prior being spread the conveyor pal- lets front the ignition unit which generally oil fired. (Blast furnace natural gas more often used steel mill installations.) Both mag- netite concentrate and the fuel are stored silos and are distributed the desired proportions rotary feed- ers directly onto the belt supplying the pug mill. Clifton presence some pyrites the ore results sulphur content 4.7 per cent maximum. This acts fuel and the anthracite percentage altered accordingly. Sulphur the sinter not over 0.040 per cent. Once ignited, combustion main- tained drawing air through the bed which about in. thick. Hopper type collectors under the wind boxes entrap fine dust which de- livered series spouts with vacuum discharge flaps collecting belt which returns the fines the pug mill.’ Combustion the anthra- such sintering machines see “Design and Operation Modern Sintering Plants,” part report the annual meeting the Asso. Steel Engineers, Ace, Oct. 1944, 73. the installation Crockett wet magnetic separators National plant Tahawus. THE IRON AGE, February 1945—55 . 4 HERE 600,000 tons magnetite concentrat cite practically complete and for brief interval the concentrate brought the fusion point. This together with the fact that the burn- ing this low ash fuel leaves voids produces porous sinter cake which breaks into large lumps drops off the end the pallet conveyor and slides down grizzley bars into awaiting freight car. There the sin- ter immediately quenched with water sprays. source complaint from the railroads that this quench- ing not always effective might be, resulting the paint being burned off the hopper bottom freight sides. Improper loading the cars has been another cause complaint. Un- less the high gravity sinter loaded directly over the trucks each end the car, the heavy material likely the car framing. During for instance, one scrapped six cars that developed “saddlebacks” cause. Greenawalt Sintering Unit The DPC sintering plant Taha- wus differs from others installed the Adirondacks that the non- continuous pan type. this Green- awalt unit, means traveling hopper car concentrate mixed with anthracite culm spread depth in. over grate pan measuring ft. The bed then fired traveling ignition machine which has three motor driven oil atomizers. Special heat resisting fans encased cast steel housings create vacuum 56—THE IRON AGE, February 1945 in. water under the bed. Fusion the concentrate practical- complete the end min., when the pan rotated 180 deg. and the contents dumped hopper bin below where the induced draft com- pletes the burning all traces anthracite and ultimately cools the sinter that can handled into freight cars without water quenching. Discharge from the bottom the hop- pers roll feeder which breaks the sinter cakes into lumps about there are three, yields about long tons sinter per cycle. Fines drawn through the grate bars are recovered cyclone dust collector and re- turned the concentrate silos. Because the more complete burn- ing the fuel obtained through air cooling the sinter, necessary against per cent for water quenched sinter and harder and more dense sinter said result. fact the product more nearly comparable with lump ore which must have sufficient density sink through the slag layer the open hearth. Such new application sinter has yet demonstrated, but experi- mental operation shows great possibilities. Lump ore carries premium ton over sinter this grade. This economic advan- tage would offset the higher cost this plant under wartime conditions when reinforced concrete and cinder block was used place cheaper structural steel and plate construc- stockpiled feed the new DPC sintering plant just getting into operation Nationab Lead's Development Tahawus. From the above lengthy description, should clear that iron mining the Adirondacks not wartime flash the pan. Recent have proved that high grade prod- uct can supplied the blast fur- nace. The vast ore resources, yet hardly scratched, and the large in- vestments private well public capital confirm the future the in- dustry. While decisions the taking over the DPC installations. private industry have yet made, the terms the various leases are favorable ac- quiring the properties. The royalties. per ton charged rental the DPC are applicable reducing the initial cost the installation, although there are provisions for minimum residual value which must recovered the government and for annual charges the capital invested dur- ing the years government owner- ship. Where new facilities were put. alongside old, obvious that the lowest operating costs are tained in. the government owned plants. surplus capacity exists- after the war, this factor costs may make the old plants surplus, rather than the new. Furthermore, with returning veterans, mines and concentrators operating now only partial capacity, because lack manpower, can operated full blast, thereby bringing costs more competitive position with those Lake Superior ores delivered the blast furnace. q } | | “ Ste Was She Cer dir q . ful one aes fur q lationab iption, nining artime ations.. prod- fur- yet in- in- lations. the ac- DPC annual: dur- put. that owned irplus, rmore,. and only ack full ore ose the dome, LEFT view nace. RIGHT bell ond saucer, creased much has been written about “the largest blast fur- nace the world.” thought that “the smallest the world” might least stimulating. According the British Iron and Steel, working model blast furnace was constructed the works the Shelton Iron, Steel Coal Co., Ltd., Stoke-on-Trent, for the Iron and Steel Industrial Research Council the British Iron and Steel Federation. Certain special researches under the direction the Blast Furnace Com- mittee were undertaken which full Hence the birth the one-eighth scale working model Fig. shows general view the furnace, the dimensions which are: Hearth diameter ....... 1ft.9 in. Height top bell Throat diameter ....... 2ft.2 Bell diameter .......... in. 90° Bosh diameter ......... ft. in. Number tuyeres...... Diameter tuyeres..... in. Building the furnace proper was commenced plinth constructed with several courses in- sulating bricks the top it. This made the taphole, cinder notch and tuyeres ft. ft. above ground convenient height for opera- With the exception tuyeres and the stack was not supported in- 4 ER the bosh. The bosh was not rein- forced, but steel bands were fastened around the stack—no casing the shaft being used. The dome, bell and saucer (Fig. were simple mild steel welded con- struction, with two gas offtakes meet- ing centrally over the bell, the top gas going waste through bleeder. The hot blast main was steel tubing lagged with insulating material, the furnace obtaining hot blast via in- sulated pipeline from the ordinary hot blast main the furnace plant. The tuyeres and blow pipes were fabricated one piece out hydrau- lic piping welded together. They were cooled town water and discharged into circular bosh built around the furnace the usual way. Metal was allowed run into miniature pig bed (not shown the illustration) with capacity four 112-lb. pigs. Slag was allowed run the floor. was well supplied with instruments. Straight line blast temperatures could obtained bleeding cold wind through valve controlled pho- toelectric cell. Twin automatic stock rods were provided give continu- ous record burden movement. addition, there was the usual para- phernalia the modern blast fur- naces—blast temperature, pressure and flow recorders, top gas tempera- ture pressure and CO, recorders and others. the onset some operating diffi- culties were encountered, chief among these being loss heat from the hearth. was found necessary surround the latter and the bosh with insulating bricks, wall eventually being employed, when af- terwards surprisingly few operating difficulties were met. The furnace was charged with graded coke and Northamptonshire Ironstone with about per cent and per cent the flux being per cent limestone and per cent dolomite. Flushing and tapping times were regular, some 448 560 lb. slag being run from three flushes over the cinder notch per cast iron (about 336 lb.) every hr. The following are the operating de- tails: Ore charge ........ 20-25 lb. approx. Limestone and dolomite......... Blast temperature ......... 400 deg 200 cu. ft. per min. Coke consumption, 4000 5000 per ton approx. Total iron made (13 weeks) tons (about tons per week). Approximate analysis iron: 2.4 1.50 0.30 0.30 0.35 Approximate analysis slag: FeO CaO MgO The furnace was blown continually for weeks and put out injecting steam into the tap hole and then rak- ing out. THE IRON AGE, February 1945—57 4 : J ox i g Magnesium Alloy facilitate the preparation magnesium alloy specimens for metallographic study, the procedure described herein was developed the laboratories the Dow Chemical Co. formulas and description the microscopic appearance the chief structural features the commercial alloys are included aid the inexperienced metallographer. meet the problems arising from.the increased interest the metallography commer- cial magnesium alloys coupled with the difficulty obtaining trained metallographers, routine method for the preparation and examination these alloys has been developed. George, metallurgist with the Dow Chemical Co., Midland, Mich., de- scribes the procedure the August issue the ASTM Bulletin. Because magnesium and its alloys polish very rapidly, care must ex- ercised prevent scratching and cold working the surface layer. Grinding done aloxite cloths Nos. 50, 150 and 320 and emery paper No. The aloxite cloths and paper are mounted disks rotating over oil tanks. The oil catches the dust generated during the grinding opera