The Iron Age 1945-02-08: Vol 155 Iss 6

IRON AGE ‘and Director Vol. 155, No. February 1945 Advertising ° ° British Developments Cam Turning.................. bal Age Hardening Alloy Eliminates Solution Treatment.... Ave. Brazing Low-Alloy Tool Tips with Powdered CHILTON COMPANY Features Soviet Wartime Ore Supply 104 WPB Official Opposes Work Fight Law.............. 116 Foresees Year-Round Air Conditioning................. 120 Westinghouse Plans Welding 124 Car Workers Granted Wage Increase 132 Electric Iron Output 132 Machine Tool Market Developments .................. 140 Non-Ferrous Metals News and Prices................ 142-143 Iron and Steel Scrap News and Prices................ 144-145 Comparison Prices Week and 146 Finished Iron and Steel, Steel 147 Warehouse, Semi-Finished, Tool Steel Prices.......... 148-149 7 4 4 ‘ Ryerson Wartime Steel Service Prompt Deliveries from Plants Ryerson stands for steel quickly from stock—and has since our Company was founded 102 years ago. Now eleven strategically located Ryerson Steel-Serv- ice Plants serve the nation’s principal steel-using areas—anything piece many carloads—bars, shapes, structurals, plates, sheets, tubing, etc.— carbon, alloy, Allegheny Stainless and tool steel. present our service cannot always fast nor our stocks complete under normal conditions. Nevertheless, stocks are large and deliveries generally satisfactory. Where item not stock our nearest from one our other plants. Very often are able give unusual service and help avoid factory machine shut-downs. Our latest stock list describes our com- plete line—more than 10,000 kinds, shapes and sizes steel. This buying sizes, weights, specifications and cutting extras for every kind steel. Our nearest plant will glad furnish you copy. JOSEPH RYERSON SON, Inc., Steel- Service Plants at: Chicago, Milwau- kee, Detroit, St. Louis, Cincinnati, Cleveland, Pittsburgh, Philadel- phia, Buffalo, New York, Boston. plant, usually can shipped RYERSON STEEL 38—THE IRON AGE, February 1945 | q 4 i Feb. 1945 VAN DEVENTER Président and Editorial BAUR and General ° Editorial Editor ....... OLIVER Editors WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Assistants NZER O'CONNOR MILLER HANSEN DAVIS LLOYD Pittsburgh 428 Park Bidg. Chicago 1134 Otis Bidg. DONALD BROWNE EUGENE HARDY Washington National Press LLOYD Cleveland 1016 Guardian BRAMS 2310 Weodward Ave. OSGOOD MURDOCK Francisco Market ROBERT Cincinnati DEAN Buffale FRAZAR Boston HUGH SHARP Milwaukee SANDERSON RAYMOND KAY Los Angeles JOHN Birmingham ROY EDMONDS JAMES DOUGLAS Purchasing Power From Price Reduction ERHAPS the most thought-provoking material that has crossed the last months are two papers Roland Soule. One these, entitled and Employment,” was delivered the luncheon the Division Industrial and Engineering Chemistry the annual meeting the American Chemical Society New York, Sept. last year. The other, entitled and Industrial Trends,” was given him recent meeting the Industrial Re- search Institute. Both these should read executives who are interested postwar planning and trends. The former has been re- printed from “Chemical and Engineering News,” the American Chemical Society, and the latter from Research,” publication the Textile Research Institute New York. Space does not permit adequate presentation the author’s views expressed these two papers, but would like dwell for moment the need cost and price reduction which emphasizes requisite expanding our boundaries postwar purchasing power. will pass over the obstacles such reductions presented both organized labor and government, which are well stated Mr. Soule and present what appears pertinent criticism modern man- agement. Speaking the characteristic phenomenon big business today, namely the divorcement ownership from management, Mr. Soule says: “Salaried officers tend regard themselves trustees for their stockholders. But the psychology the trustee primarily conserve and protect and not take risks except last resort. result, became the instinct too many executives improve quality rather than lower prices and emphasize defensive economies rather than ag- gressive expansion. “Many large corporation,” continues, “therefore failed dis- charge its duty, not only its stockholders, but the country whole. failed demonstrate any economic justification for its con- tinued existence—a responsibility which, according recent study made the Brookings Institution defaulted unless it: ‘Accepts and vigorously stimulates cost reduction, volume enlarging and quality im- proving techniques and passes these benefits into the consumption channel fully and promptly.’ Prewar examples industries which followed this policy, the benefit the public and ownership, and labor well, are automotive and oil. one familiar with business history the past several dec- ades can doubt the efficacy this policy stimulating growth em- ployment and enlarging markets. Our postwar job cut costs and prices all our industries. will certainly not gain the necessary additional employment looked for unless do. course, government must help this, not subsidizing pri- vate business public employment but amending its policy from one discouragement and intimidation one encouragement risk taking. Excessive taxes, for example, are double acting cost and price increasers and purchasing power diminishers. They hit both the pay envelope and the cost sheet. tw q Unit Blled War ming He’ll Explain the Advantages Inland “Made Order” Sheets Na’ When Inland specialist called in, count Your sheet forming problems will simpli- him tell you about Inland “Made fied when you take advantage Inland thin Order” Sheets sheets that are specially Sheets. processed fit the that elimi- Inland Steel Company, Dearborn St., nate the waste cut-and-try methods Chicago Sales Offices: Cincinnati, Detroit, sheets that are economical because they Kansas City, Milwaukee, New York, St. Louis, help production start faster and iss Bars, Floor Plate, Piling, Plates, Rail, Rein- ols. Inland specialist will help you select the forcing Bars, Sheets, Strip, Structurals, Tin right sheets for parts that are the design Plate, Track Accessories. ring stage well for parts that already are production. will help you prepare specifica- tions for Inland sheets which will processed for your particular requirements base metai, temper, surface, etc. These specifica- on, tions will studied the Inland mills. nate sheets will processed under close metallur- gical control, and they will thoroughly tion inspected before shipment. Inland sheets, proc- essed for you, will uniform quality, gage, size, and workability sheet sheet from order order. News FRONT More than 300 Belgian plants including steel and foundry units that have escaped damage have been restored production are now turning out war supplies United States Army and troops other Allied nations under reciprocal aid Steel mills there are rolling rails, I-beams, and other material for and for the reconstruction bridges and tracks. One mill has already 7000 tons steel rails. Department steel requirements will reach all time high for the second with demand excess 4,500,000 tons. Third and fourth quarter steel will probably still higher. While military procurement will only about $1,000,000,000 higher this year year, steel demand will much greater because the items now needed use much steel. This increase will reflected boosts the following programs: landing mats, aircraft, trucks, tanks, heavy artillery, drum and bombs and rockets. believed that Republic's direct reduction unit Warren, now turning out satisfactory grade iron. However, continued need for some the equipment. being done, and proposal will made DPC this week additional expenditure of, perhaps, $200,000. exports from the the months ended November was $2, 730, per cent above the same period 1943. This least three times value British exports for the whole year. And: Imports into the for the same months amounted out $800,000,000 more than exports. Ignoring which ite feat, this represents the unusual condition exporting more than importing. Nearly 2000 British airmen who had land France during the occupation got Britain with the help the resistance movement. Some the American airmen ming through the same way tell rugged experiences, that being prevented from rrendering the Germans and having commit overt acts satisfy vement members. Some tens thousands German deserters are hiding inside the Reich and ousands have crossed into Switzerland and Spain. Most deserters are from the Navy, with Luftwaffe deserters the minority. However, recent German internal broadcasts complain that German pilots who thin Germany are disappearing, and ask that civilians forward numbers pieces uipment that pilots may identified. The broadcast also complains that German too readily strip German aircraft for souvenirs. The ratio British and airplanes all types operating the Western ont about German fighters attain speed 620 miles per hr., according iss report. Such speed compels the pilot lie prone position the ols. The German War Production Board was advised Dec. that V-3 would ready for ring against the the end December. It's currently overdue. Now that the has big supply robot bombs about ready for use against rmany and Japan, there now more talk robot bombs being wanton instruments depraved State bent senseless destruction. Naturally the robot bombs will much more accurate and efficient. Additional details the German V-2, rocket bomb, indicate that the combus— on, jet, derived from four fuels, namely, hydrogen peroxide, calcium nate, ethyl alcohol and liquid oxygen. These fuels are stored tanks. The direction the jet stream controlled carbon vanes over which the tion gases pass. Mild steel used throughout the rocket and effort made the weight down. The outer shell duraluminum. Provision made for the stratosphere. When the rocket hits the lower altitudes speed close miles pér hr. the friction great that whole rocket becomes has been observed glowing red during the latter part the descent. k | 4 4 q 7 4 i J 3 | | | | Treatment Pistol Parts preferred," appears many Ordnance draw- ings today. Those parts that cannot made tougher with greater impact strength adding strengthening radii radi- cal design changes, can austempered the liquid bath meet severe service conditions. ° ° ROY ELLIS Chief Engineer, Remington Rand, Inc., “C” Division, Syracuse, ASS production has one weak- ness inflexibility. Design changes one point can dis- locate hundreds processes all down the line. Arbitrary abrupt design changes can, fact, produce some- thing crisis. Consider, for ex- ample, the indirect effect copper and shortages upon the design the government model caliber 0.45 au- tomatic pistol. Development steel cartridge cases the Ordnance Department and ammunition makers required ob- vious minor modifications barrel chambers and extraction mechanisms small arms. Such changes were readily made, but more formidable difficulty was disclosed when was found that the extractors existing design were longer meeting endur- ance tests the firing ranges. changes for increased strength of- fered solution, because any new modified extractor must continue interchange every detail with ex- i 42—THE IRON AGE, February 1945 ° OINT isting pistols all branches the service. not generally realized that modern small arms produced un- der the supervision the Army Ord- nance Department are far superior endurance and interchangeability those made during the first world war. This does reflect the trend toward interchangeability already far advanced production methods. But its flawless perfection today due primarily the close contact between the Industrial Branch the Small Arms Section and the skillful planning and cooperation the engineers the Pistol Industry Integration Committee. Nevertheless, was this very factor perfect in- terchangeability which problem critical one. clearer visual understanding the function extractor may had from Fig. What not ap- parent the fact that the extractor, which W.D. 1075 steel, with required Rockwell 58-63, besides having thick and thin sections function point failure extractors are shown here. The car- the firing chamber. ° ° ° abruptly blended, also fitted form gage the final phase manu- facture. That is, must bent just enough impart the positive spring action which helps press the hook down onto the cartridge case extrac- tion ring. Steel cases, expanding and taking slight set the barrel chamber, imposed extra burden the extractor and caused excessive breakage the point indicated, close the hook end. The actual structure the steel that point breakage shown the photomicrograph, Fig. This after standard heat treatment speci- fied that time. would appear have been suitable for the service encountered generally, and was produced holding the extractor temperature 1500 deg. for min., then quenching oil and tem- pering for hr. The suggestion that isothermal treatment liquid baths might improve the service life this part was made metallurgical con- ferences Walter Bolton, consulting metallurgist the Wycoff Drawn Steel Co. Opinions were means unanimous, however, view the thick and thin sections, sharp corners, and the pronounced warping which seemed unavoidable under the old method, for which atmosphere fur- naces had been utilized throughout. For another article see THE Aug. 31, 1939, 21. Since there were many theoretical differences opinion, was agreed experiment for confirmation practical tests, and 100 extractors were austempered, first heating immersion liquid bath 1500 deg. F., followed transfer an- other liquid bath held fixed tem- perature 600 deg. The struc- ture secured shown Fig. (Nital etch, 1000 diameters). These photomicrographs are worthy study those who specialize minute differences index physical properties. Comparison with the previous structure itself, but the actual changes physical properties disclosed upon me toa manu- just spring hook anding barrel Jen close teel speci- ervice tor for tem- that baths this ulting means the rners, which old 21. greed actors 1500 an- struc- Nital orthy with upon 2—Structure secured old quench-and-temper methods the point fracture conventional for 1075 steel used the extractor part. 1000 diameters, Nital etch. mechanical and service testing were not short phenomenal. Not only were all the extractors accurately gage after the process liquid baths, with required hard- ness all testing points, but when held vise close the extraction hook, these extractors could bent hammer blows inward outward from the cartridge deg. angle without fracture. Extractors having the structure shown Fig. frac- tured very readily. Twisting the en- tire length four terms did not cause fracture any point the iso- thermally treated samples. (See Fig. Inasmuch these rough mechan- tests showed decided progress ‘the direction physical properties desired, the next test was made en- guns, which were fired di- rectly under the supervision the residence inspector. The result significance the evolution this and similar components, will seen. extractor, selected quite ran- former point fracture Scarcely clue the enormously superior toughness isothermal methods. the part given the metallography this section near the hook end the extractor. dom, was given prolonged endur- ance test, which was continued 32,900 extractions. When removed from the gun, was found that the hook extraction lip was altogether free distortion, and set loss spring tension had taken place. The extractor likewise fitted the forming gages perfectly, se- vere service had taken place. This performance was extraordinary seem.incredible designers and engineers directly concerned. order eliminate the possibility that this extractor was not typical, supply extractors austempered the liquid bath was sent all pistol facilities for endurance tests and re- port. These and others tested showed extractions 15,000 and 20,000, with 4—A clear view the extractor part, with its thick and thin sections, points failure under quench and temper, and superior physical properties after treating isothermally. * * deformation whatever the ex- traction hook, and loss spring tension. Moreover, all them fitted the original bending gage they had just come from production. With these performances established, all doubts were removed, and the tests were accepted conclusive. now mandatory austemper extractors described. Since this isothermal method liquid baths has been use, reports from all over the country reveal that only two extrac- tors have broken the regular Ord- nance endurance tests. One was caused seam stock; the cause the other failure could not de- termined. During this period many hundreds thousands extractions have been made under strict inspec- tion. that isothermal treatment has turned out the means salvaging many thousands extractors which had been made before the necessity structural changes developed. Tests THE IRON AGE, February 1945—43 : = conducted with such salvaged parts, after careful annealing and austem- pering described, showed bur- ring the extractor lip. These parts likewise fitted the form gages after endurance firing 15,000 rounds. one prolonged endurance test find the ultimate breakdown point, the test extractor held for nearly 30,000 extractions. failure was observed, but was considered un- necessary continue the test. other words, the breakdown limits for that part have not yet been de- termined. Procedure Liquid Baths The isothermal procedure was first set the plant the Remington Rand “C” Division, Syracuse, view the heat treating de- equipped for all types heat treat- ment which might required any component the caliber 0.45 pistol, either for immediate comparisons and metallographic tests, for standard production large scale. The two immersed electrode salt bath furnaces shown Fig. are the Ajax-Hult- gren design with closely spaced elec- trodes, the isothermal bath being shown the left, with the smaller high heat furnace the right. The high heat furnace has round ce- ramic pot, with depth in. and kw. rated power input. The larger furnace has rectangular steel pot with working bath area 36x20x16 in. furnaces are equipped with thermocouples and re- cording pyrometers, and both have the same salt depth order ac- commodate the variety fixtures 44—THE IRON AGE, February 1945 5—General view the heat treat- ing department Remington Rand Division, Syracuse. variety equipment shown, permitting all types heat treatment for production comparative methods utilized. and parts for which isothermal treat- ment has been adopted. fixed 600 deg. temperature maintained without difficulty and the mass average charges introduced 1500 deg. from the high heat furnace never large enough cause temperature rise. Extractors, being peculiar whiplike shape, clearly seen Fig. are held the butt end special fixture devised engineers the Ajax Electric Co., Philadelphia, who also designed and manufactured the two furnaces. The entire cycle takes less than min., including unloading and loading time, well the cold water rinse. This compares with hr. required under the old method quench and temper, the main time saving being omission the hr. tempering period, fewer cleaning operations, and superflu- ous handling. The web fixture holds extrac- tors, and closeup view its con- long handle for convenience swing- ing charges between the two baths and stop for fixed immersion depths in. below the surface the salt, measured from the top portion the part which undergo treatment. Only one loaded fixture immersed high heat bath time. After average min. this tempera- ture, the charge swung the iso- thermal bath furnace. This holds five loaded fixtures, that one full charge comes off every min. when the production cycle has begun the first shift. average min. the 600 deg. fixed temperature bath required for full austemper- ing, with some degree latitude either way allow for the human factor when only one operator charge this process, frequently occurs. Electric salt baths this type are simple and economical operate, and since there are explosion hazards excessive radiated heat, operators. prefer the austempering assignment any other the department. Tem- perature control, important this and similar processes, simple that all that required the setting dial. Temperature variations are all below the deg. specified the furnace makers anywhere the bath. Heating perceptibly faster, and the total absence distortion has marked the most important gain addition the enhanced physicals. Upon withdrawal from the 600 deg. bath, the fixture load given single dip-and-lift-out cold water rinse. This washes both the fixture and the parts completely free salt. Much less handling required than formerly, since longer necessary re- move quenching oil films. Excellent surface finish maintained and the parts are readily Parkerized, re- quired. The fixtures are special heat-resisting alloy, and they show wear deterioration under thou- sands severe and repeated high and low heat cycles immersion fol- | ° ° the iso- holds five one full when the min. iperature istemper- latitude human tor requently type are rate, and hazards operators. signment nt. Tem- this simple setting the faster, listortion mportant enhanced 600 deg. nse. This the parts less formerly, re- Excellent and the re- special show thou- ted high rsion fol- lowed further cooling the cold water. Because the vertical suspension parts these fixtures, salt drag- out relatively unimportant. amounts approximately 150 lb. per month, including both types salt, and includes total dragout for va- riety parts, averaged high per day, over period six months. perceptible electrode pot wear has been observed date. standard brand neutral salt used for the 1500 deg. bath, and stand- ard tempering type salt used the isothermal bath. Other Parts There are other parts the gov- ernment caliber for which austempering has offered the most effective means prolonging service life beyond all previous ex- perience. Perhaps the most interest- ing, view the great shock and impact stresses encountered, the component known the barrel bush- ing. Its function less complicated mechanically than that the extrac- tor, may seen from its struc- 1075 steel, heat treated 50-60. secures the end the gun slide and supports the barrel muzzle. Its function includes that the locking lug, which only 0.091 in. thick and which must withstand the powerful instantaneous backward thrust the gunslide action when the pistol fired, and the forward thrust from the heavy recoil spring the slide returns the full recoil position. The service stress for that lug has been calculated pounds and best described re- peated peening hammer-blows con- centrated the lug itself and pro- ducing dual flexing action the point where this thin lug joins the body the bushing. Fig. also shows how this lug usually fractured, after approximately 5000 breakdown firing tests with zipped-up modern ammu- nition. Experience with the uniformity liquid bath heating for austempering the extractor, with its own thick and thin sections, led similar experi- mental and testing procedure with the barrel bushing. Temperatures used were increased deg. the high-temperature isothermal quench bath, other temperatures and the time cycles all remaining the same. Rod- type fixtures the type shown Fig. were devised for suspending immersion. 6—Closeup view the two salt bath furnaces used the isothermal process. .Both furnaces have the same salt depth. Controls pyrometers are placed near the furnace for operating convenience. After treatment and metallographic examination, bushings were likewise test fired and then submitted all national facilities for endurance tests under strict Army Ordnance supervi- sion. One these test bushings was used three pistols. Each was fired 15,000 rounds. After surviving to- tal 45,000 rounds, this bushing showed minute check under Magna Glow. The check was found the bushing body itself, however, and not where failures had been occurring the lug juncture. was placed an- other pistol and submitted another endurance test 10,000 rounds, without observable failure wear. These outstanding cases have shown that when part cannot made stronger adding strengthen- ing radii sharp corners, radi- design changes, can accom- plished austempering the liquid bath. The practicability the method seen the fact that yet have not had any rejects due distortion hardness discrepancies. One by- product effect has been the increased service life pistols generally. Dur- ing the first world war, 2000-round endurance tests were standard. Early the manufacture this pistol, endurance test 5000 rounds was adopted. Today 10,000-round test conducted once month. This in- service life, which now taken matter course, would not have been possible the func- tional life extractors had not been THE IRON AGE, February 1945—45 ais ot ° ° ° increased 32,900 extractions steel shells, and that the barrel bushing well over 45,000 rounds. Thus seen that austempering liquid baths not only increased to- tal pistol life, but has been further observed that when the bushings are hardened racks, that the liquid salt full contact with the inside and outside sections well the heavy locking lug and locking collar, all warping was eliminated. series two test runs 1500 were made, using special testing fixture before and after austempering, and only three pieces were out round. Pre- viously, was regular operation test and correct out round barrel bushings. This longer necessary. Indeed, the improvement distor- tion these components was no- ticeable that the process was tried 46—THE IRON AGE, February 1945 pension for the barrel bushings, utilized the iso- thermal process de- scribed the text. Note thinness the complete contact with the molten salt with inside and out- side sections. high heat- salt bath ment. Long handle out four other parts, including the safety lock, ejector, disconnector, bar- rell link and firing-pin stop plate. Samples that were correct gage when soft were austempered the liquid bath outlined above, while others the same group were treated the former method hardening and tempering. The rejections dis- closed test gages the austem- pered parts was extremely small that the old method was discontinued once, and recognition this time and cost saving found all gov- ernment blueprints 8—Barrel bushings, showing rela- tive size and thickness the which carries the discharge and recoil impact each complete movement the recoil mechanism. hardening procedures. The words, “Austempering preferred,” appear many pistol drawings today. Thus seen that method which first was considered theoretical and even debatable many metallurgists and designers has proved the only practical way meeting the rigid Ordnance tion, with fewer rejects after heat treating, parts which could not, perhaps, have been improved this degree, tolerances and inter- changeability permitted. The whole project has been importance it- self during critical phases the war, but see field for further research here Remington Rand improve the mechanism lower overall costs for regular peacetime products. Such the years come. words, appear which retical and tallurgists the the inspec- after heat could not, this and inter- The whole ance it- the war, research improve erall costs ucts. Such value = British Developments Cam Turning EVERAL interesting design prin- turning lathe for multiple throw automotive camshafts, developed the British firm Arthur Scrivener, Ltd., Birmingham. indicated Fig. each individual tool (there may and out motion which controlled master cam, several times the size the product, which rotates the same speed the work. The roll- follower standard straight roller bearing. can seen Fig. however, the tool shape quite unconventional that has radius the vertical face the nose. order that the form traced out the point the tool will the approximate shape for which the master cam designed, the radius the tool point and the radius the tool follower have definite relationship each other. The cutting action the tool ac- axially along the camshaft. fundamental for the production accurate work this method that the correct radius maintained the tip the tool and that the center line this radius always the proper height. Production time determined the material and the amount stock removed. the case many conventional automobile engine cam- shafts, single traverse the tools produces finish turned camshaft sufficient accuracy obviate all sub- sequent operations except heat treat- ment and final grinding. Usually, all the cams may produced the same time, thus assuring accurate timing well high production. this way camshaft for four six cylinder automobile engine can machined floor floor time min. maximum. Camshafts may produced this machine from bar stock which has been previously necked between the cams from forgings. plan view the machine shown Fig. and rear view Fig. The latter shows the hydro-mechan- ical arrangement for giving infinitely variable feeds the tools. thrust pin Spring adjusting locking Camshatt AS profile being produced circular blank cut Tool block tion tool slide profile lathe. Wor and master set cams are driven the same speed. Cutting edge face Length production reciprocates 2—Diagram showing generating ac- tion special tool used cam profile lathe. view Scrivener automatic camshaft turning lathe, showing 24- throw aircraft camshaft being machined throws time. 4—Rear view the machine, showing the master camshaft and the simple hydraulic longitudinal tool feed. THE IRON AGE, February 1945—47 4 Radius too! Simplifying Computation existing wage and hour legislation coupled with vari- ous clauses labor contracts which guarantee overtime premiums time and one-half for all time worked. excess hr. per day hr. per week, problem arises these overtime premiums con- cerned. Apparently industry has taken this situation stride and perhaps also for granted, with thought the direction simplifying this compli- cated computation. far known the usual proce- dure with perhaps few minor devia- tions follows: (1) Compute total earnings straight time basis for total hours worked. (2) total hours are excess eight, the total earnings for the day are divided the number hours worked find the average rate per hour. (This applies incentive workers hourly rated workers have definite hourly rate.) (3) This average rate per hour then divided two determine the half rate per hour com- puting overtime premium multiply- ing the half rate per hour the number overtime hours. Even though the above procedure not mathematically complicated is, however, method which requires great deal time the part time clerks. this so-called “lost time” making these computations, the writer has prepared chart, Table showing total number hours worked and multiplying factor which when used with total straight time earnings will furnish total over-time premium in. one simple computation. (This same method can also used earnings hourly rated workers with accurate results.) Because most time clerks have cal- culators available extend earnings, etc., this one multiplying operation can completed even before the first 48—THE IRON AGE, February 1945 advantage dividing operation could started under the old method. dividing these premiums for various accounting charges ever present. TABLE Factors for Use Calculating Overtime Premiums Worked Factor Worked Factor 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.0 oooooooceo cee example and comparison old and new methods follow: Old Method Compute total straight time earn- ings with perhaps result $11.56 for day 9.8 hr. The total earnings $11.56 then divided 9.8 hr. for aver- age $1.18 per hr. This $1.18 per hr. divided would result half rate per hour $0.59. Then the final computation would the multiplication the half rate, $0.59 per hr. 1.8 overtime hours. 0.59 1.8 hr. would result total overtime earning $1.06. New Method Compute total straight time $11.56 the example above. Multiply $11.56 the factor shown beside 9.8 hr., total hours worked, with this result: $11.56 0.0919 (9.8 hr. factor) $1.06, total overtime earnings. Therefore, from the example shown, this simplified method may seen, far sav- ing time concerned. The range hours worked this chart shown from 8.1 12.0 hr., most cases this ample cover average overtime work. However, possible extend these hours cover any possible combination that may needed compute overtime earnings excess hr. per day. connection with the computation overtime earnings, the problem Total Overtime Total Overtime Worked Work Factor © 6.4.0.6 46 © 6-4 course when entire overtime earnings for any one employee charged only one account di- vision earnings necessary. How- ever, number cases these earn- ings must divided between two more accounts due regulations established certain accounting methods. conjunction with this problem Table has been compiled aid this process and based the same principle, that multiplication faster than combination division and multiplication. Again using the first example, far overtime earnings are con- cerned, which showed the overtime premium $1.06 with 1.8 overtime and supposing that 0.6 hour charged one payroll account and 1.2 hr. another using the old method, again would become necessary divide 1.8 into $1.06 find the half rate per hour. This could used extending the pre- mium for each account, the result would follows: $1.06 total over- time divided 1.8 hr. $0.59 per hr. This $0.59 per hr. would then used extension multiplying same 0.6 hr. and 1.2 hr. respectively. New Method Multiply total overtime earnings ($1.06) the factor shown for 1.8 overtime hours (0.556) with result $0.59 per hr. The final computation would then made shown under “old method.” Therefore, each the above 0.0062 0.1397 0.0123 0653 0.1429 0.0181 0699 0.1461 0.0239 0745 0.0295 0790 0.1522 0.0349 0834 0.1552 0.0403 0877 0.1582 0.0455 0919 0.1611 0.0506 0960 0.1639 1000 0.1667 | various resent. overtime ployee di- ary. How- hese earn- two egulations accounting problem aid the same division mple, are con- overtime overtime 0.6 payroll ther using uld become $1.06 our. This the pre- the result total over- $0.59 per uld then same ectively. earnings for 1.8 result would then method.” the above cases the long process division eliminated and simple multiplica- tion substituted. order complete the process simplification, the problem com- puting overtime earnings for the sixth day was presented. computing the premiums for the sixth day, the entire day’s work receive time and one half compensa- tion, necessary only multiply total earnings 0.50 compute over- time premiums. However, again due existing legislation, the worker does not have regular hours the end the first five days, given work week, any time worked the would paid straight time basis; consequently when condition such the above exists only the hours excess hr. for the week would paid for time and one half. factory working fairly uniform hours these conditions not arise very frequently, but when they do, they must reckoned with and again the old method dividing and mul- tiplying would called upon. this case the two previously presented cases Table III was pre- pared which when used with the total straight time earnings for the sixth day and multiplied the factor shown beside the total hours worked, results the half rate per hour. This half rate then used extending total overtime earnings Overtime ° ° ° Gorski South Bend, Ind. ° ° ° Although not mathematically complicated, the computation overtime premiums frequently time consumer. Therefore, this simplified method has been devised, the result being greater acy with greater speed. for the sixth day multiplying this half rate the number hours which are receive time and one half compensation. Example Man working hr. the sixth day, but receive time and one half for only 6.8 hr. Total straight time earning for sixth day, $8.64. $8.64 0.0625 (factor for hr.) $0.54 half rate per hr. This half rate ($0.54) multiplied 6.8 hr. would equal $3.67 total over- time premium for time excess regular hours worked the sixth consecutive day given work week. Therefore, the simplification program outlined the foregoing article based simply the proven fact that time clerk with the aid can multiply faster and produce more accurate results than possible when both division and mul- tiplication must employed. TABLE Factors Used Where Overtime Earnings Are Charged More Than One Account Total Overtime Hours Multiplying Factor o 83238 TABLE Total Overtime Hours Multiplying Factor Factors Used When Calculating Premiums Work Done Excess 40-Hr. Week When Time and Half Applies Total Hours Total Hours Worked Factor Worked 4.0 0.1250 5.2 4.1 0.1220 5.3 4.2 0.1191 5.4 4.3 0.1163 5.5 4.4 0.1137 5.6 4.5 0.1112 5.7 4.6 0.1087 5.8 4.7 0.1064 5.9 4.8 0.1042 6.0 4.9 0.1021 6.1 5.0 0.1000 6.2 0.0981 6.3 Multiplying Total Hours Multiplying Total Hours Factor Worked Factor Worked 0.0962 6.4 0.0782 7.8 0.0944 6.5 0.0770 7.7 0.0926 6.6 0.0758 7.8 6.7 0.0747 7.9 0.0893 6.8 0.0736 8.0 0.0878 6.9 0.0725 8.1 0.0862 7.0 0.0715 8.2 0.0848 7.1 0.0706 8.3 7.2 0.0695 8.4 7.3 0.0685 8.5 0.0807 7.4 0.0676 8.6 7.5 0.0667 8.7 Multiplying Total Hours Multiplying Factor Worked Factor 0.0658 8.8 0.0568 0.0650 8.9 0.0562 0.0641 9.0 0.0556 0.0633 9.1 0.0625 9.2 0.0544 0.0618 9.3 9.4 0.0532 0.0603 9.5 0.0527 0.0595 9.6 0.0521 9.7 0.0516 0.0582 9.8 0.0575 9.9 0.0505 10.0 0.0500 THE IRON AGE, February Factor 0.1397 0.1429 0.1522 0.385 0.370 0.357 0.345 0.333 0.323 0.313 556 0.303 0.294 500 0.286 476 0.278 455 0.270 0.435 0.263 0.417 Recent Developments Swaging cipally have brought three changes the meet specific needs. First, the cable swager produced for years Standard Machinery Co., Provi- dence, for attachment shank fit- tings has been redesigned into fast, automatic die opening and automatic feeding unit requiring only sec. for each operation. Second there the Hydro-Former, used not only for swaging ball fittings cable, but also for the attachment tube solid fittings, balls rods, hose flexible tubes and for finishing wide range circular forms from tubing and bar stock. Lastly, Standard has developed for the Navy all-pur- pose swager for attaching aircraft fit- tings steel cable that now avail- able for general use. The automatic cable swager, Fig. has increased production the at- automatic die opening cable swager showing centering guide, die control lever door and foot pedal that sets work feed into action. 50—THE IRON AGE, February 1945 times through the use quick act- ing die opening device and automatic feed, with the resultant elimination the extra operator formerly required and the necessity removing dies for each cable swaging operation which large end fittings are used. There are other operations production manu- facture which this adapted, such swaging shank fit- ting around rod tube attach- ing tubing pin type fitting an- other smaller diameter tube. While the cable swager utilizes the rotary swaging action for working the shank metal the fitting around the cable strands, the operation simplified hand control for opening and closing the dies from the front the machine while running. The cycle operation consists pass- ing the fitting that loosely hung over the end the cable through the open dies into the adjustable feed socket. With the cable end held firmly against the bottom the fitting, the handle the door front swung vertical position start the swag- ing action, the foot treadle released and the work moved automatically from back front through the dies the completion point. which time the dies are opened. Fittings are given smooth surface, Fig. and are swaged firmly the cable that the fitting and cable strands appear fused. Four sizes Standard cable swag- ing machines are offered handle cable sizes from 1/16 in. The numerous applications the Standard Hydro-Former, Fig. are accomplished the use hydrau- lically operated wedges, making possible one operation shape metals without cutting and join them without rivets welds, Fig. The wedges are retracted for the in- sertion work and then advanced— foot automatic control—to close the dies at. speeds each job. wedges advance, the pressure the dies the work increased the point shaping solids atttaching fittings plastic flow. When the forming operation complete, the wedges are retracted and the dies are thrown open cen- trifugal force. Adjustable work stops vided within the spindle for the con- trol dimensions. Automatic wedge control may provided that the work positioned and comes con- tact with the work stop, the close the dies. hollow tube whose advance retrac- inder. Speed die closing adjusted regulating valve governing the pressure the system and fluid pres- sure directed either end the cylinder pedal control valve. The hydraulic pump driven off the rear the main drive motor. swaged cable cab swager. i ° ° ° retracted cen- the con- atic wedge that the 1es con- retrac- cyl- adjusted the pres- end the valve. The the rear fittings ble swager. Tube Attach Three sizes and designs the Hy- dro-Former are available. The No. bench model weigh- 140 lb., has manual wedge opera- and designed for use tubing in. and bar stock in. diameter. The No. machine, weigh- ing 3300 handles tube sizes in. and bar sizes in. diam- eter, while the No. unit weighs 27,100 lb. and will form tubing in. diameter and solid stock in. diameter. The special all-purpose swager, pri- marily designed for light jobbing duty and repair work, corresponds size Standard’s regular No. 4A, and adapted cable work any size from 1/16 in. through series die changes and multiple swaging Each step necessitates stopping machine with quick acting brake replacing dies with the next size. Ordinarily, fittings are step about min. with No. weighing 26,000 lb. con- the all purpose model, which only 3800 requires three steps and approximately minutes. These three designs have adopted the principles rotary swaging NEW precipitation hardening al- loy per cent copper, per cent nickel and per cent manganese Co., Detroit. Among the prop- claimed for this alloy are its resistance and uniformity heat treatment. Although more than half copper composition, has silvery color and presents surface when polished. alloy said soft and duc- and can either hot cold into intricate shapes and then 750 deg. Hardening any degree between dead soft and full hard Metal Forms from Solid Ay ‘Tube Fittings RIGHT 3—No. Hy- dro Former show- ing V-belt drive, hy- draulic pump and foot pedal for wedge control. production uses that are said per- mit economies manufacture here- tofore unknown. Automatic feeds can arranged for handling the work through the swaging cycle that low labor cost can held. Also, the produced varying the time the single aging temperature which may varied 100 deg. without affecting the resultant hardness. hardness 400 Vickers can readily obtained, claimed, aging either dead soft cold worked Physical properties corresponding this hard- ness are: Tensile strength, 200,000 lb. per sq. in.; yield stress for 0.1 per cent offset, 170,000 per sq. in., and proportional limit 120,000 lb. per sq. in. Freedom from drift and high fatigue strength make the alloy espe- cially useful spring material. For full anneal, hardened parts may heated few minutes ° ° ° LEFT 4—Typical applications work done Hydro Formers. ° ° maintenance costs are low since the hammers, dies and rollers that with- stand per cent the force the working are cheap and readily re- placeable. The initial capital invest- ment also low. Age Hardening Alloy Eliminates Solution Treatment temperature between 850 deg. and 1100 deg. reharden material softened this manner, only necessary repeat the aging treat- ment. The elimination solution treatment pre-requisite aging greatly simplified the heat treating procedure and accounts for much the uniformity physical properties claimed for the alloy. This material, known No. 720 Manganese Alloy, available all the forms which stainless steel usually supplied and recommended for use corrugated diaphragms, bourdon tubing and temperature pressure responsive bellows. THE IRON AGE, February 4 Refractory Molds For Precision Casting The author concentrates the refractory mold the critical feature the process, and has amassed much information the binder used for high temperature investments. ° ° JULES GLASER Yonkers, characteristic qualities precision castings—dimensional accuracy, surface smoothness, intricate design possibilities, repro- duction fine detail, coupled with ex- cellent metallurgical and physical properties—are attributable, the main, two features the process: The method used for the prep- aration the refractory mold which receives and the charge molten metal. The application pressure upon the metal while solidify- ing the mold. This pressure, usually provided centrifugal force spinning mold air pressure stationary mold, generally greater than can con- veniently attained the applica- tion risers and headers em- ployed foundry practice. The advantages pressure casting have gained ever widening recognition recent years. The gains yield and the improved metallurgical characteristics the castings have, indeed, impelled foundries adopt -centrifugal casting techniques wher- -ever suitable particular products. the purpose this article discuss some the pertinent con- and techniques which ap- the production the unique refractory molds employed preci- -sion casting. The principal steps the molding are: The formation expendable wax plastic replicas the object cast, separate pattern being IRON AGE, February 1945 ° ° required for each single casting The aggregation number such patterns around main feeder means appropriate sprues. The imbedding (investing) the pattern aggregate plastic semi-liquid refractory mass (in- vestment) retained metal cyl- inder (flask ring). The elimination from the in- vestment material air and excess liquid binder order obtain dense refractory mass and con- tinuous, smooth, closely adherent surface against the patterns means vacuuming, vibrating, and/or tamping. After the mold has set, the utilization the expendable pat- terns produce the cavities which will receive the molten metal—the procedure which has given rise the name, “lost-wax process.” matching the two halves soft metal mold can accomplished the use encasing rings and dowel pins. :Mold metal terns. The formation satisfactory pendable patterns most crucial the attainment the desired precision castings. The exactnes size, surface detail and with which the metal castings capable reproducing the pattern: immediately precludes the possibilit obtaining perfect castings with spect these characteristics unles the most rigid control and inspectio brought bear upon the patter department. The first important factor affectin results this department the typ mold employed form the Three classes molds recognized, namely: rubber mold: soft metal molds (Wood’s metal, robend, etc.) and steel molds. The facility and speed with whic rubber molds may made woul seem warrant serious consideratio for them. However, their lack rigic ity and high shrinkage upon ization limit their application case where dimensional accuracy cidedly secondary importance, the case most jewelry items. Greater dimensional accuracy achieved the soft metal mol but necessary make maste pattern, incorporating shrinkage lowances and machined much rower tolerances than might missible for the castings from it. Experience great variet parts indicates that the cost master pattern plus the cost soft metal mold closely the cost steel mold mak the latter the preferred choice. thermore, the soft metal mold has relatively limited productive life The application heat and pressur through repeated injections wax, soon causes distortion nificant extent and the exposed edges are rounded off, unless the rigid supervision exercised. some extent failures caused forcing the split halves together unmatched position may minimiz encasing the mold permanent split shell made alu pin isfactory ex- results exactness and contour castings are the patterns, possibility ‘ings with re- ristics unless inspection the pattern ctor affecting the type orm the pat- molds are and providing proper vents. Where molds, metal, Cer- molds. with which made would consideration rigid- upon vulcan- ation cases racy de- rtance, accuracy can metal mold, master shrinkage al- much nar- might per- made great variety cost the approaches make choice. Fur- mold has life span. pressure, hot sig- exposed sharp nless the most reised. caused together minimized etal mold nade alumi- num, bronze steel, and fitted with dowel pins sufficient length guide the two halves the mold into match- ing position before the soft metal sur- faces come into contact. (See Fig. 1.) One economical use the soft metal mold that determining ex- act shrinkage allowances sub- sequently made the more costly steel mold. For this purpose stock part suitable master pattern, since dimensional comparison the stock part and the casting produced from will the precise shrinkage across all sections. These figures can then added the di- mensions specified the blueprint and the steel mold made according- ly. Rubber and soft metal molds under certain conditions have proved very useful devices the precision casting shop but their limitations defi- nitely point the use steel molds for accurate production work large quantities. Locating Sprues The choice mold type having been made, attention must next paid the location and size sprues large flat areas are presented the surfaces particular and especially where such surfaces occur over fairly massive cross-section, one the most common failures the expendable pattern the partial collapse such surfaces into concav- ities. The greater the shrinkage char- acteristics the wax used and the greater the cross-sectional area the pattern, the more pronounced will this effect, other fac