The Iron Age 1945-03-08: Vol 155 Iss 10

Editorial ond Advertising Offices VAN DEVENTER President and Editorial Director BAUR General Manager LEONARD Assistant General Manager HAYES Advertising Manager JOHNSON, Manager Reader Service and Market Research CLEARY, Technical Research and Promotion Manager ° Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd Cleveland Pittsburgh 1016 Guardian Bidg. Park Bidg. Philadeiphia icago Chilton Bidg. 1134 Otis PEIRCE LEWIS WARREN RAYMOND KAY Los Angeles 2420 Cheremoya Ave, ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Offices Chestnut and Sts. Philadelphia 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH GEORGE GRIFFITHS EVERIT TERHUNE DEVENTER BAUR Vice-President FAHRENDORF Vice-President WILLIAM BARBER, JOHN BLAIR MOFFETT, Secretary CHASE HARRY DUFFY BUZBY THOMAS KANE CHARLES HEALE Member, Associated Business Papers Vice-President Vice-President Vice-President Vice-President Indexed the Industrial Arts Index. lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, Copyright 1945, Chilton Company % Vol. 155, No. AGE March 1945 Editorial ° ° ° Technical Articles Unionmelt Welded Anchor Production Galvanizing Ammunition Shear Strength Copper Brazed Joint................. Impact Resistance vs. Hardness Aircraft From Forged Breech Rings Castings................. Plastic Blind Rivet Extrusion Copper-Base and Aluminum Wooden Models Aid Machine Design............... ° ° ° Features Personals and Obituaries ..................... ° News and Markets Overseas Surplus Control Changes................. Industry-by-Industry Surplus Solution 132 136 Industrial Supremacy Becoming 140 French Steel Will Recuperate Rapidly.................. 144 Machine Tool Market Developments.................. 154 Nonferrous Metals News and Prices................. 156-157 Iron and Steel Scrap News and Prices.... .......... 158-159 Comparison Prices Week and Year............... 160 Finished Iron and Steel, Steel 162 Warehouse, Semi-Finished, Tool Steel Prices......... 164-166 Steel Pipe, Tubing, Wire Products, 168-169 Stainless Steel and Ferroalloy 172 ° ° ° 6c. i | } 860. Because large tonnages the 8600 and 8700 series alloy steels have been used successfully for wide range applications and have shown excellent mechanical proper- ties and desirable response both fabrication and heat treatment, the American Iron and Steel Institute now registers these standard AISI alloy steels. The AISI prefix will replace the designation but the numbers will re- main the same. Ryerson selected the 8600 and 8700 series alloys the start the (National Emer- gency Alloy) program. Large stocks have been built and full range sizes are available for quick delivery from Ryerson stock. Ryerson alloys you get this plusservice: With each shipment alloy steel, you re- ceive report, which includes chemical analy- sis, grain size, working temperatures, Jominy Hardenability Test results, and physical prop- erties interpreted from hardenability for various sized rounds quenched and tempered three different draw temperatures. The report per- tains specifically the heat alloy delivered. All bars are identified according heat, with painted color markings and stamped heat sym- bols, which correspond the identification noted the report. Thus Ryerson offers uniform, high quality, plus complete working information that en- ables you heat treat correctly without further testing re-testing. Call Ryerson for 8600 and 8700 and all other alloys well carbon and stainless steel products. RVERSON STEEL JOSEPH RYERSON SON, INC., STEEL-SERVICE PLANTS: CHICAGO, MILWAUKEE, 54—THE IRON AGE, March 1945 Presid Vice-Pre Editor Technica Commer DETROIT, ST. LOUIS, CINCINNATI, CLEVELAND, PITTSBURGH, PHILADELPHIA, BUFFALO, NEW YORK, ESTABLISHED (855 ° ° March 1945 ° ° ° VAN DEVENTER President and Editorial Director BAUR Vice-President and General Manager ° ° ° Editorial Staff Technical Editor ......... OLIVER ° ° ° Associate Editors WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Editorial Assistants SCHIEN VAN CAMP MUNZER O'CONNOR MILLER HANSEN DAVIS News and Technical Editors LLOYD Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis Bldg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press LLOYD Cleveland 1016 Guardian Bidg. BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT Cincinnati DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle REMINISCENCE ONVALESCING Atlantic City sunshine after what has appar- ently been successful bout with pneumococcus and having not much else think about, one’s mind turns reminiscence. Normally you not get time for that. have been thinking about shop experiences years ago and what and have our industrial plants today that did not then. those days, which not seem long ago, aside from few special tool steels, knew alloy steels. There were just two kinds steels that encountered the day’s work: low-carbon and high- carbon. did not even call them that but recognized them soft hard. The soft steel was what made things of; the hard steel was what made them with. Choosing the hard tool steel used the shop was quite job those days. There were dozens supposedly different brands the market and eloquent super-salesman represent each one. not recollect that any these steels were copper-bearing but their salesmen certainly had plenty brass their make-up. Lacking any scientific means checking these various claims, would hold cutting tool competition once year. number these tool steel salesmen would invited bring samples their wares and pit them against the other fellows’. shaft forging would put between centers lathe; speed, feed and depth cut chosen and the tool that lasted the longest got the business. future shipments did not always live the sample. But was fun anyway and needed little that break the monotony the 10-hour day, 60-hour week. Oil salesmen, particularly those who sold cutting oils, were the same category. Very few plants indeed, those days, had testing lab- oratories and selection was largely foreman’s choice and matter opinion, plus sometimes the passing ten dollar bill from one hand another. Shop life those days had its drawbacks but there were compensat- ing advantages. Plants were smaller for one thing and more personal- ized. and large, spite long hours and smaller pay think that the them were more contented than the workers today. they did not have much time think about their troubles. perhaps was because the art trouble making had not yet been developed. From the ore ranges, the coal fields, and the limestone beds are coming vast quantities blended iron ore, coking coal, and purest the principal ingredients for making steel, the both peace and war. Today this steel must all into the production the materiel war, but tomorrow, when Victory ours, finer things will come from out the ground because im- provements now being made Inland metallurgists are constantly testing and re-testing, melting and re-melting, adding one element and taking away another—always seek- ing for something better. Already they have contributed many new methods and new steels produc- tion for war. These, and the newer methods and Inland steels that are sure come from continued intensive research, will help you meet the needs America peace. INLAND STEEL COMPANY South Dearborn Street, Chicago Illinois Sales Offices: Cincinnati Detroit Indianapolis Kansas City Milwaukee New York St. St. Paul ave mac the nes ob’ su) thi = News March 1945 The War Department announced,this week the existence the P-80 "Shooting single engine jet plane designed Lockheed, and powered General Electric gas engine, presumed have gone into combat. production four plants, the combat hope the AAF for this war. the international aluminum cartel interest the Senate's Business Committee, connection with the light metals hearings. Particular tion being paid Alcoa's alleged connection with past years through Aluminum Co. Canada. Attention being paid light metals fabricators' demands that competition Alcoa fostered the government. The Canadian enterprise, financed largely RFC, now equipped with its own power produce aluminum cheaper than anyone else the world, hangs heavily over the postwar head the industry this country. Steel, plywood, and aluminum tents are now being manufactured experimentally for the Army, and successful, may importantly change the market situation any those fields. Abandonment all part the Alcan highway imminent, according reflecting the extensive maintenance required keep open, and the reversed cal situation Alaska and the Aleutians. The Engineer's Corps' new aluminum bridge may Eisenhower's the Rhine crossings. Designed for speedy erection swift currents, they would used for the establishment bridgeheads, replaced later Bailey type Failure the Boeing plants meet production schedules thd B-29 program has. brought WPB Chief Krug the scene. Labor turnover the chief trouble. Boeing has been hiring 3000 new workers monthly while average 2500 month have been quitting. gas burners utilizing carbureted mixtures higher than normal pressures has made possible large heat releases small burner concavities. The combustion reaction confined within the burner itself that flame exists the heating chamber beyond the face the burner block. These ceramic burners make possible the use continuous compact heat-treating machines that are clean and occupy very little floor space. Tests SAE X4130, 4140 and X4340 show that there straight line between resistance impact and hardness. These tests also lead the conclusion that any low alloy steel this heat treated certain ness tensile strength, approximately the same Izod impact resistance value obtained regardless the alloying elements present the steel. Impact resistance values salt quenched materials were also shown than those corresponding oil quenched specimens. Because Sweden longer receives imports German iron and steel, has divert high grade steel facilities the production commercial grades. steel now constitutes about per cent total output, while prewar years, duction high grade steel exceeded that commercial grades. Plans increase Swedish production iron and steel are complicated Supplies scrap iron and coke. imports coal and coke cannot resumed the period July July 1946, domestic charcoal will have used much possible the blast furnaces. Army Ordnance the European theater operations for Army Groups have recently been estimated 6205 combat vehicles, 34,250 general vehicles, 166,885 rifles and other small arms, 23,871 mortars and machine and 75,245 binoculars, watches and compasses. Enemy equipment reportedly captured destroyed far exceeds total battld losses. For example, according Ordnance reports, the Third Army has reported about twice many Panzer tanks captured known have been destroyed their own battle losses. addition, General Patton's report that they have destroyed tured pieces enemy artillery for every one lost. + | | | | SS | = | j pi Thins Continuous Heat Treatment The development all-ceramic burners handling high-pressure carbureted gas-air-mixtures has opened new vistas heat treat- ment. High speed, automatic continuous units, clean and very com- pact, are being developed for bar and strip stock both ferrous and non-ferrous industries. HARRY SMITH, Jr. Selas Corp. America, Philadelphia developments gas com- bustion engineering are being eyed with exceptional interest producers and users rod, tube, bar, and strip—both ferrous and non- ferrous—because not without pos- sibility that many fundamental con- cepts heat processing this field are for revision. For one thing, continuous heat 58—THE IRON AGE, March 1945 treatment through small units, which more closely resemble machine tools than furnaces, promises supplant much batch treatment large heavy car-hearth, conveyor, bell pan-type equipment—an end desirable from the standpoints both floor space and smooth efficient routing production. For another, rates heat transfer into work have been accelerated that the times during which metals are under heat can cut and cut again—and the deleterious effects time-at-temperature (such scaling, ‘decarburization, dezincing, etc.) can minimized. Finally, possible construct “hell-holes” for continuous heat treat- ment sufficient capacity handle considerable tonnages stock single-line transit (length after length endless procession) and insure that each length (of rod, for example) transverses the same path the same speed through the same hell-hole—to undergo the same heat treatment, inch-by-inch along its length and rod- by-rod throughout the production run. Also, continuous spray quenching the purposes hardening, preventing oxidation, stopping phase precipitation, simple cooling—be- comes convenient without large tanks, hoists, and handling machinery. ° ° 1G. unit for continuous heat treatment stainless tubing 5.3 ft. per hr. ° ° ° ° ¥ 2—Structure stainless steel tubing 250 diameters. Before heat treatment, left, showing the results cold work; after heat treatment, right, showing annealed structure. Etched aqua regia. Already the new heating techniques which promise such evolutions are being applied: (1) the annealing cold rolled rod and bar, welded tubing, seamless tubing, extruded nonferrous materials, and finned stainless steel tubes; (2) the hardening pre- heat-treated stock; and the brightening electrodeposited tin steel strip. The combustion engineering de- ° ° end continuous unit for steel, showing housing the quench- velopment itself hinges about the use all-ceramic gas burners utilizing completely and accurately carbureted gas-air-mixture supplies higher than normal pressures. such burn- ers possible obtain large heat releases small burner concavities, through employment the insulating and refractory qualities ceramics insure completion the combustion reaction within the confines the burner itself, that flame (as such) exists the heating chamber beyond the face the burner block. applied high speed heating cell through which rods, bars, tub- ing are processed, the construction in- volves many such burners crowded closely possible around horizontal cylindrical chamber from in. in. diameter and long re- quired for the heating effect desired THE IRON AGE, March ; | (13 in. ft. units far de- signed). Thus, immense heat re- lease closely fitted about the traveling work piece attained, and the “ther- mal head” (or temperature differ- ential) between the walls the heat- ing cell and the surface the work significantly multiplied. some in- stances the internal cell temperature The great acceleration heating rates procurable with such construc- tion can attributed two effects: First, the above mentioned higher thermal head, and the greater rate radiant heat transfer associated there- with (proportional the difference between the fourth powers the ab- solute temperatures radiator and second, the very greatly reduced space between the inner walls the heating chamber and the work, contradistinction normal furnace practice. result, the products combustion whip through the cell flue very much greater lineal ve- locities (for roughly the same volume through very much smaller passages). Thus, the rate heat transfer the work convection (proportional the speed the hot convection medium past the heat-receiving sur- face) also multiplied importantly. applied the heat processing strip, burner arrangements are, course, not cylindrical, but the form facing flat panels, closely spaced either side the traveling strip. The characteristics the heating process are the same rod tube heating, both the radiant and 60—THE IRON AGE, March 1945 4A—Doughnut spray for continuous quenching welded steel tubing, diameter. Production about 180 per hr. convected components heat trans- fer being greatly accelerated over normal furnace methods. All-Ceramic Burners Obviously, such highly compacted and intensified combustion would fuse metal burner constructions, and, in- deed, the work itself were stop slow down unduly. Therefore, the developments under discussion have had await the perfection ized all-ceramic burner designs—in- volving the invention techniques molding and firing close-tolerance ceramic parts great complexity and varied composition. This factor, probably more than any other, ex- plains why sufficiently high speed gas combustion has not heretofore been successful—despite the admitted pro- duction, metallurgical, and economic advantages progressive heat treat- ment through small combustion units. Actual calculations, designs, and equipment may help interpret the new techniques terms rod, tube and strip production. the installation shown Fig. the heating cell in. long in. square, centrally located through thick overall. Ten radiant-ceramic- cup burners fire into the cell from the top, bottom and sides, and liberate within the cell less than 300,000 B.t.u. per hr., tantamount million B.t.u. per hr. per cu. ft. cell volume. Through this cell steel tubing in. o.d. and in. bore, finned depth 1/16 in., during continuous transport lineal rate 5.3 ft. per min. (six- teen ft. lengths per hr.). Ton- nage amounts 160 lb. per hr. The heat treatment 2150 deg. and followed precision spray quench water and short flood- cooling run immediately beyond the cell. The metallurgical structures be- fore and after annealing are shown Fig. Hardness was reduced 62- than required. The outlet side the cell (showing the housing around the quenching unit, and the air gaps the four drain lines from the water-cooled feed rollers and end-plate castings) central Fig. The run-out table, 4B—Doughnut spray for continuous quenching welded steel mounted, serves also large and convenient reservoir for quench water. Prior service producing the finned stainless tubing, this unit was tested also for the continuous anneal- ing in. diameter and in. diameter tellurium-nickel-brass rods temperature 1550 deg. and lineal transport speeds in. per min. and in. per min., respectively —the hardness results being B10-12 Rockwell uniformly along the ft. lengths, across cut sections the stock, and from rod rod. The unit shown Figs. and similar, with cell shape in. commodate various sizes welded steel tubing from 5/16 in. diameter in. diameter. Speeds tube travel through the unit vary from 2/3 ft. per min. ft. per min. (97 sec. down sec. time-under-heat for any particular section metal), de- pending, not tube diameter, but tota pro Fig spr whi per tee eac Fig tot pre att dis tel time unit). prevent any sag tubing during heating, and keep centered the cell all times, the unit designed that two cells, each in. long, are end-to-end with water-cooled supporting roll between (see Fig. 5B). this case the en- trance unit takes the tubing approximately 1100 deg. and the exit unit achieves the ultimate 1950 deg. required. Here, the tubing seamless, size range from in. in. diameter, and quench water thermostatically controlled 165 deg. Twenty-eight radiant-cup burners, altogether, vent into hell- in. diameter and liberate 2,750,000 per hr. Adjustment for locating tube travel centrally within hell-holes for different size tubes raising lowering the heating themselves (by means jacks incorporated the structural supports). the unit shown Fig. 4A, the other hand, the heating unit remains stationary and the feed and exit rollers are adjusted instead. Continuous Nonferrous Unit Shifting attention from the ferrous the nonferrous industry, the unit shown Fig. interesting. Its cell has average diameter in. and in. long, long that the two water-cooled supporting rolls must pierce the firing chamber itself (their inlets and bearings being visible just below the nameplate Fig. 6B). Here bars and rods various brass and copper alloys, and diameters from 5A—Two-cell unit for continuous heat treatment seamless tubing. Total time unit sec. The entire unit raised and lowered jacks accommodate different size tubing. in. are annealed rates total metal mass (which follows the 5B—Same unit Fig. 5A, showing the water-cooled supporting roll between product wall thickness girth). the cells, which prevents sag the tubing and keeps the tubing centered. spray) for larger sizes tubing, while Fig. shows the same for the smaller sizes tubing. This par- ticular cell designed for production ranging from lb. per hr. 180 lb. per hr. gas consumptions from 21,000 320,000 per hr. Six- teen burners fire into the hell-hole, each with its own shutoff cock (see Fig. that only fraction the total cel] capacity need utilized for processing the small diameter tubes. The design the unit that maximum efficiency and production attained with tubes in. in. diameter, which the user’s major production requirement. Annealing temperature approximately 1950 deg. Fig. still another unit, for similar but higher production—lineal speeds ft. per min. (only sec. heating time, and sec. total THE IRON AGE, March 4 } = a 6A—Continuous unit for heat treating bars copper alloys. Bars are from in. diameter and are handled rates ft. per min. from ft. per min. ft. per min. (93 sec. down sec. time- under-heat). Thirty-two all-ceramic radiant-cup burners liberating 765,000 per hr. are employed. The unit itself ft. long ft. di- ameter overall, neglecting feed and run-out tables. The unit designed for cell temperatures 2800 deg. beyond the melting point any the alloys involved—a funda- mental conception behind the new class high speed heating units, and one which emphasizes the necessity IRON AGE. 1945 for accurate coordination between pre- cision firing and precision work-feed- ing rates. The many converging water jets from the doughnut spray ring are clearly visible Fig. 6B, the 18-in. water-flood tunnel just beyond it. The techniques just described are applicable any commercial gas— the units shown Figs. and utilizing manufactured gas 530 per cu. ft., that Fig. em- ploying natural gas 1100 per cu. ft., and that Fig. oper- ating propane 2550 B.t.u. per cu. ft. The first application the latest evolution such rod heat treatment “on the fly” through compacted-gas- combustion “cells” still under con- struction, but remarkable because slated for use the continuous hardening pre-heat-treated steel rounds rate 480 per hr. and sizes from in. diameter in. diameter. this instance two units will used end-to-end with the spray quench ring between—the former heating for hardening 1550 deg. F., and the latter for drawing 1150 deg. Preliminary tests and designs indicate rod speeds from ft. per min, 21% ft. per min. Each the two units will have heat- ing cell in. long, and in. long overall. The hell-holes will rough- rectangular and approximately in. in. Thirty-two burners are being installed the hardening unit and burners the drawing unit. quench ring being designed with 320 holes 1/16-in. diameter, total orifice area only 0.992 sq. in. (66 per cent quench-water-line internal cross-sectional area). Ad- justable dampers are being provided the flues each cell for close regu- lation cell pressures. Construction will embody ceramics able with- stand protracted heating 3000 deg. The operation this pilot plant will watched with considerable interest, particularly regards the time-temperature relationships and metallurgy the draw operation. There little doubt about the success the hardening cycle. both are successful, interesting chapter production pre-heat-treated stock may written. Developments panels, such shown Figs. and are yet embryonic—their success- ful application date being confined the flow-brightening tinplate. The panels shown each employ 6B—Same unit Fig. 6A, showing the two water-cooled supporting rolls which pierce the firing chamber support and center the rod. 4 “a the 7A—Radiant burner panel unit for the flowing tin electrolytic tinplate. The burner groups are zoned that different heat patterns can used for different strip widths, closely spaced radiant-cup units rectangular mately ft. wide ft. long. Tin- panels running rates 500 ft. per min. noteworthy that whole burner groups are zoned, that dif- ferent heat patterns can used for different strip widths. Modulation the total heating effect each panel automatic motor-driven move- ment nearer further away from the strip. Advantages over electric induction methods are claimed be: More rapid modulation heat input with variations strip plating thickness, markedly lower installation and operating costs, and higher pro- duction speeds. such techniques are mentally projected into the fields continuous strip annealing. and finish coating, other startling opportunities suggest themselves. If, further, the possi- bilities similar heat transfer are contemplated terms heavier work (billet, ingot, bloom, and where laboratory batch experiment has already demonstrated the feasi- bility unusual heating speeds with acceptable temperature uniformities employing close-fitting envelopes intensely-fired ceramic burners—the horizons for revolution rolling mill, forging, and heavy steel heating seem truly infinite. 7B—Assembly two heating panels for flowing tin coated strip. The strip passes between the panels, and the panels float supports, the distance from the moving strip being constantly varied pyrometers. = fi Indeed, heat-treatment-on-the-fly presents new promise worth watching. Cold Rolling High Strength Steel Strip effect rolling tempera- tures from —298 deg. 392 deg. the tensile properties, de- formation, resistance, magnetic prop- erties, tendency corrosion and structure strip, 0.088 in. thick, following steels: (1) 0.05 19.6 9.1 (2) 0.06 15.4 14.5 (3) 0.13 15.0 1.1 16.4 (4) 0.19 14.4 0.22 18.7 (5) 0.57 0.7 1.0 (6) 0.25 0.7 1.0 0.23 und 1943, vol. 63, Nov. 25, pp. 853-60; Dec. pp. 880-85. The deformation resistance the austenitic steels sharply with increasing reductions per pass, but this resistance could reduced with rape oil lubrication. The defor- mation resistance also increased with decreasing temperature. Steel (1) attained its maximum tensile strength when reduced small amount each large number passes. One chromium-manganese steel and nitrogen treated chromi- um-manganese steel attained ten- sile strength almost 270,180 per sq. in. The strength these steels, however, was much less after heavy reductions few passes. Steels (1), (5) and (6) attained tensile strength 177,750 213,300 per sq. in. after cold rolling. When the austenitic steels (not ni- trogen-treated) were given heavy re- ductions per pass, the magnetic sat- uration value reached maximum and then decreased, but when reduced small amounts per pass this value steadily increased. the cold roll- ing the austenitic steels, the mag- netic transformation was markedly dependent the temperature. re- lationship could found between the phase condition determined mag- netic saturation values and the sensi- tivity intercrystalline This sensitivity decreased with in- creasing deformation. THE AGE, March 1945—63 | INCE reliable strength first requisite for anchor chain used maritime services, Blaw-Knox Co. turned automatic submerged melt welding rapid and economical means making the thousands inter- mittent individual welds chain fabrica- tion its Columbus plant. When ft. lengths in. chain are subjected tensile strength test 157,000 Ib. failures rarely occur the points that have been automatically welded. this application Union- melt welding demonstrates its adaptability rapid, repetitive work the line fabrication cumbersome product which its finished form must withstand rigid Navy tests and inspection before be- ing used. Photograths courtesy Linde Air Products Co. ABOVE Each alternate link anchor chain made from bar stock and forged stud. The other links the chain are forged shown the top. ° ° ° proper length for bending and welding. LEFT 64—THE IRON AGE, March 1945 — 4 j . 4 } ¥ th ABOVE forged links are placed fixture the bending machine and the heated bar inserted through them and bent shape. The bending operation leaves V-shaped space required for the auto- matic welding. the links are formed, the spool until (90 has been made. shot consists forged links and bent links. ABOVE IG. 5—As the formed chain fed from the spools the battery Unionmelt welding ma- chines small wad steel wool inserted the opening the links provide the electrical con- tact for starting the welding operation. Reels 5/16 in. welding wire and the welding transformers are located balcony above the welding sta- The transformers deliver 1600 amp. volts each head. RIGHT 6—The link welded fed into the welding machine and stud laid one the water-cooled copper clamping shoes, shown open this view. The welding wire fed down contact with the steel wool. THE IRON AGE, March 1945—65 7—Closing the shoe alines the stud with the open ends the bent bar. Welding then takes place under blanket Unionmelt flux and completed sec. The weld metal literally cast place metal mold. 66—THE IRON AGE, March 1945 BELOW IG. 8—This shows the completed automatic weld. joins the ends the bar and also anchors one end the center stud. LEFT While the next link being welded, the welded link goes hot milling machine adjacent the welding station, where the red-hot excess metal removed from the weld. BELOW the testing pit each fathom shot given tension test 157,000 Ib. shot must weigh less than 1690 and must exactly fathoms long within tolerance plus minus in. From every fifth shot four extra links are cut off and tested destruction. The breaking load 235,000 minimum. the final inspection, any six links must meas- ure in. long, with tolerance plus minus 5/32 in. This close tolerance necessary assure that the chains will not bind the the anchor wind- lass shipboard. finished chain next placed annealing furnace and about hr. BELOW 13—Upon acceptance the chain dip painted trough and loaded railroad cars for shipment. LEFT From the hot milling op- eration the chain fed steel chan- nel trough, where the other end the stud manually are weld- adjacent station the trough excess metal from the arc welding operation ground off the chain which then wound spools for transfer the first inspection table. Here receives company inspection and preliminary Navy inspection. 4 provide protective coating for steel ammunition cases made hold mm. anti-aircraft shells for the Navy has been interesting development. The production sched- ules have been large and the variety parts small, that speedy proce- dures could devised. Early contracts were placed with manufacturers who had little previous experience hot galvanizing. the subject open-mindedly, intent using the methods, materials and equipment that would assure volume production satisfactory product. fundamental changes the hot galvanizing process were required. They The problem the start was vanize these cases, complete, the rate 50,000 per month and its solu- & q Galvanizing 7 r a tion required the selection the proper method and equipment. The cases are made sheet steel formed and welded approximate size more than Ib. each. chafing strip reinforces the top edge and in- side the case are various cross mem- bers welded the shell and used hold the place. There are covers having movable members means which they are locked seats provide water- tight elosure. many instances, these have and have been assembled after plat- ing. other cases they have been partly hot galvanized and partly The quantities involved have such permit familiar meth- ods production plating used. ° ALLEN BALDWIN Hanson-Van Winkle Munning Co., Matawan, The procedure finally installed the plant the Ferro Stamping Mfg. Co., Detroit, illustrated part the accompanying pictures, The cases arrive the galvanizing department lightly coated with oil, free heavy scale, but having some spots light rust and welding oxide film. Their surface, therefore, closely similar that the sheet metal wares commerce they ar- rive hot galvanized. The gen- eral preparatory procedures are the same, except that the No. flux used make flux wash, rather than muriatic acid. The simple sturdy rack shown Fig. was developed carry units ten cases and covers from the starting point through all the pre- paratory treatments and delivers its preparation bodies and covers. Stamping Mfg.Co. IG. used Photo Ferro af 4 Cleaning, pickling and flux load the galvanizing kettle without intermediate handling transfers the load. The rack parts which are submerged have generally been made acid-resisting alloy. The cases are supported long rod and are held place toothed piece the inner end which holds the case firmly inclined position assure thor- ough draining. The complete preparation the work for the hot galvanizing takes place the series tanks shown Fig. The first step clean the cases hot alkali cleaner which takes place the distant end the series tanks Fig. The subse- quent steps are rinse water, pickle, rinse again and dip the No. flux wash. The rack finished cans the front the picture al- lowed stand permit excess flux wash drain out and the desired protecting flux film form. The cleaner moderately strong per gal. about boiling temperature, the steel tank which appears Fig. The consumption cleaner the order 0.2 per oz. per case and cover cleaned. The rinse tanks are also made steel, while the pickle tanks are made wood and have facilities for heating their contents without causing dilu- tion the contents these tanks. The pickle sulphuric acid and varies different plants from per cent per cent deg. sul- phuric acid volume. The pickling generally done about 160 deg. The cold water rinse following this pickling important step and the operators have quickly observed that thoroughness here has led better flux wash life and cleaner ac- tual galvanizing. The more com- pletely the residual pickle acid and ferrous sulphate are removed from the work the rinse, the lower the dross production and the smoother and more ductile the coating well the less the tendency fused flux adhere the galvanized surface. one feature these new plants was provide generous supply cold rinse water running freely, con- stantly. The acid consumption approximates oz. oz. per cent acid per case and cover. The flux wash varies between deg. and deg. Baume and used 170 deg. 180 deg. The racks work are allowed stand this hot flux wash for few minutes permit the heat drive out the absorbed hydrogen remaining from pickling. No. flux wash deg. Baume will contain about lb. solid per gallon and when freshly made will have 4.0 4.2 electrometric measure- ment. These data are being used basis for checking the thoroughness the rinsing after pickling. Con- tamination pickle acid will lower the pH, and when this occurs the ac- tual performance each step should checked carefully. The total flux consumption flux wash and kettle flux also about oz. per case. Properly prepared cases, after the flux film has dried on, should show practically traces greenish brown areas. Such coloring generally indicates re-oxidation resulting from slow drying. Excessive contamination the flux wash also discolor the work. These imperfections are avoided easily and result superior final galvanized surface readily ob- tained. Various shapes ket- tles are being used, heated dif- ferent fuels different ways. Early installations were designed use hot circulating gases and were made wide provide space for automatic feed- ing devices installed later. The demand for immediate production and the actual results obtained using three and sometimes four crews about single kettle acted keep demand THE IRON AGE, March 1945—69 the pre- its used overs. -erro & Fig. 3—Galvanizing kettle; manual operation. for automatic feeding devices the background for long time. [Auto- matic machines for putting cases through the zinc kettle are now widespread use. device designed Hamilton Mfg. Co. generally used.—Ed. The exit end one side kettle early installation appears Fig. showing two cases being re- moved practically simultaneously. The sheet iron partition towards the cen- ter the pot forms one side the flux box. second such partition far- ther along the side the kettle com- task burning tubes shape with relative accuracy proved quite difficult until the trated was developed Chester Fabian, Westinghouse Electric Mfg. Co., Jer- sey City. cylindrical sheet metal tem- plate slipped over the tube some distance from the torch where cannot damaged and brought into contact with fixed follower pin. the burn- ing operation progresses, the template kept contact with the pin ro- tating the tube the trunnion rollers and moving the work carriage longi- tudinally with the hand wheel. The torch remains fixed position. Adopting this new setup resulted increased pro- duction and quality because layout required and there very little setup necessary. Large quantities various shaped tubes for welded structural uses have been gas cut successfully and economically. ° ° IRON AGE, March 1945 pletes the flux box and beyond the kettle appearance duplicate that shown the front the pic- ture. There ample room for two men act feeders the flux box each side the kettle that production unit can work about each the four corners the kettle, al- though three such units are commonly working. Safety provisions control flux ex- plosions have been taken the use baffles the boxes themselves. basic crew men about the. kettle three with supplemental assistance depending local condi- tions the various plants. dis- tinct point variation procedure here from that the manufacture sheet metal wares that little handling the cases done with tongs. The cases are placed the flux box the usual way for sheet metal wares, operator guides them out from under the flux box into cradle with the open end the case facing the take-out man who can exert the necessary pressure slowly and steadily lift and drain the case and obtain smooth coats. The cases are then picked up, moved roller conveyor and reversed that the open end up. Production per crew varies from about over cases per hr., those being made the higher pro- duction having heavier and rougher coats zinc them. common pick-up value for the cases oz. oz. per case. particular attention paid size uniformity spangle. Freedom from flux spots and high degree smoothness are required and obtained. Distortion the cases avoided and particular attention devoted de- tails the inner and outer surface the open ends that the covers will seat easily and perfectly. This whole procedure special application the time tried methods galvanizing sheet metal wares such ash cans and the like. espe- cially interesting because companies generally inexperienced hot gal- vanizing have been able use these methods with improvements details create high speed production units which high quality hot gal- vanizing economically. sho tifie face and mer fine cedi - Shear Strength Copper Brazed Joints HETHER not the degree surface finish the brazing interfaces has any influence the resulting joint was the ob- ject test recently terminated the engineering test laboratories the Consolidated Vultee Aircraft Corp., San Diego, Calif. Differences joint strengths were not suf- ficiently large the direction warrant conclusions concerning the influence the surface finish factor. The test specimens were copper brazed units made barrel member and ring drive-fitted over it, conforming the sketch. The specimens, number, comprised four groups samples whose surface finishes and interferences negative clearances (difference between ring diameter and barrel diameter) are shown the table below. Each group specimens was iden- respectively. Each these symbols represented the fineness the sur- face finish the machined barrels and their corresponding rings. Speci- mens with the symbol had the finest finish, and each following group was twice rough the pre- group. Results Shear Tests Copper Brazed Joints KING Engineering Test Laboratories, Consolidated Vultee Aircraft Corp., San Diego, Calif. -Ring SPECIMEN used for testing copper brazed joints consists barrel and ring drive-fitted over it. The surface finishes the speci- mens used this test were repro- duced accordance with reference samples furnished General Electric Co. The degree surface roughness these references measured microinches (millionths inch) and represents the average deviation from center line profile con- tour the surface. All specimens were tested shear testing machine using the 100,000 lb. range. general, the average shear values the test specimens with the four different finishes, inclusive, varied only slightly shown the table. However, the series, which had the second finest finish, was slightly lower shear strength. all cases the shear strength was found excess 23,000 lb. per sq. in. Because the somewhat lower shear strength values obtained the group specimens surface finish than the other three groups, second test was made check, with the substitution cen- tral solid cylinder place tube. the previous test the interfer- ence was approximately 0.001 in. Values shear strengths obtained these specimens ranged from 32,200 50,700, averaging 41,400 per sq. in, against the previous range 23,700 35,000, averaging 29,300 per sq. in. However, view the inherent microscopic irregularities fit brazing interfaces, and the physical nature the cementation process involved brazing, ques- tionable attribute the above in- creases shear strength entirely, all, the change specimen de- sign from central tube central plug. Degree Surface Finish (32 microinches) (63 microinches) (175 microinches) (250 microinches) | | Specification Interference Shear No. In. In. 0.0011 0.0011 34,300 0.0011 34,300 0.0011 38,200 0.001 0.001 39,200 0.001 32,200 0.001 32,100 0.001 37,500 0.001 28,200 0.001 34,100 Average (negative clearance) barrel diameter minus ring diameter. in. Interference Interference In. In. In. 0.001 0.001 0.001 31,400 0.001 0.001 33,100 0.001 0.001 25,750 0.001 0.0011 0.001 0.001 28,100 0.001 0.001 27,300 0.001 0.001 30,600 0.001 0.001 25,500 0.001 0.001 34,100 0.001 0.001 35,000 0.0012 0.001 0.0012 0.001 23,700 0.0013 0.001 34,100 0.0011 0.001 30,200 29,300 Shear Interference Shear In. In. In. 34,000 0.001 32,400 27,100 0.001 25,300 0.001 34,300 32,500 0.001 32,100 0.001 28,800 34,100 25,300 0.0012 35,500 35,800 0.0012 33,400 35,800 0.0012 30,900 0.0013 32,900 34,500 0.0013 36,400 0.0018 29,600 34,100 0.0018 34,400 37,900 33,100 31,900 The shear area all specimens equalled THE IRON AGE, March ° ° ° Ring Barre/ n \ ir e- INCE little information has been available the normally ex- pected impact resistance air- craft low alloy steels, the Fort Worth Division the Consolidated Vultee Aircraft Corp., Fort Worth, Texas, carried out tests determine the re- lationship between resistance im- pact and hardness for these steels well values which might ex- pected under the circumstances various heat treatments. Izod test specimens SAE X4130, 4140 and X4340 steel were subjected various heat treatments, and tested impact testing Rock- well hardness readings were then made the fractured test bars. When the impact resistance value all steels tested were plotted against Rockwell hardness values each particular steel, straight line equation was obtained. the values did not show wide scatter, was concluded that there definite re- lationship between resistance im- pact and hardness. may also concluded that any low alloy steel Draw Impact Temperature Resistance Deg. Ft. Lb. SAE X4130 this classification heat treated certain hardness (or strength), approximately the same Izod impact resistance value will obtained regardless the alloying elements present the steel. The tests also emphasized that the impact resistance values salt quenched ma- terials are higher than those corre- sponding oil quenched specimens. The specimens used this test were A.S.T.M. 10x10 mm. square Izod test bars. Test bars were cut from single pieces each the fol- lowing materials: (1) steel (22 test bars); (2) 4140 steel (22 test bars); (3) X4340 steel (22 test bars). All specimens were heated 1575 deg. and held that temperature for minutes. Eleven test bars each type material were quenched oil (70 150 deg. F.) and test bars each type material were quenched molten salt (500 deg F.) and held that temperature for min. Two specimens each type steel quenched were submitted Correlation Impact Resistance and Rockwell Hardness Data SAE 4140 Impact Hardness Resistance Hardness Rockwell Ft. Rockwell single hr. draws 600, 750, 900, 1050, and 1200 dg. Two specimens each type steel (salt quenched) were submitted two separate draws. (double-draw) hr. each 600, 750, 900, 1050 and 1200 deg. All specimens were then tested the Riehle impact testing machine. This machine delivers 110 energy the release pendulum. When the pendulum specimen, fractures and records. dial the amount energy ab- sorbed required fracture the specimen. transverse cut was then made inch from the smooth end each fractured specimen and Rockwell readings were made the positions. (approximate) shown the follow- ing cross-sectional view: SAE X4340 Impact Hardness Rockwell 72—THE March 1945 *(a) Control sample—As quenched oil 70-150 deg. *(b) Control sample—As quenched salt bath 500 deg. (held for min.). Impact values are averaged for two specimens each draw temperature. Hardness values are averages three read- ings taken each specimen, six readings for each draw temperature. Oil Quenched Low Alloy Steels the 600, Impact Resistance vs. are that twee and sligh cept read prob mat quer The men 750 —+-— -3 low wou mat tha Roc the str lov 33.2 41.5 37.0 38.1 ing 25.1 31.6 63.5 32.2 sis ri Salt Quenched Low Alloy Steels 600 32.6 13.5 46.5 900 50.5 25.3 35.9 1200 107 13.0 91.5 20.3 Alloy Steels 900, nens. hed) 600, lum. the ords. ab- the pach. ions: low- Izod impact resistance values and Rockwell hardness readings for oil quenched specimens and salt quenched specimens drawn temperatures 600, 750, 900, 1050 and 1200 deg. are presented the table. The data plotted Fig. shows that there direct relationship be- tween Izod impact resistance values and Rockwell hardness readings. The slight scatter readings along this straight line may discounted ex- cept for those readings obtained for salt quenched SAE X4130 steel. These readings are much too low and are probably due the fact that this material was not ciently the 500 deg. salt bath quench, This fact also brought out the data presented the table. The properties the control speci- mens are nearly the same those the specimens drawn 600 and 750 deg. this material were lower temperature, the would higher and the straight line equation Fig. would then show that the Izod impact resistance this material would lower. This straight line graph also shows that any low alloy steel that will heat treat certain tensile strength Rockwell hardness will have nearly the same Izod impact resistance value any other low alloy steel heat treated the same hardness and the basis this graph the approxi- mate Izod impact resistance any low alloy steel from its Rockwell hardness reading. Fig. presents the effect draw- ing temperature the impact re- sistance toughness any the low alloy .steels that were tested. apparent that salt quenched mate- have better properties than oil quenched steels, that is, salt quenched materials are tougher have more resistance impact than oil quenched steels drawn the same temperature. All the low alloy steels follow the Same curve, each one becoming less brittle the drawing temperature values obtained for all types materials tested with the ex- ception salt quenched X4130. The spread this material seems ° ° ° JOHN THOMPSON, JR. Metallurgical Laboratory, Consolidated Vultee Aircraft Corp., Fort Texas. relationship between resistance impact and hard- ness for SAE X4130, 4140 and X4340 steels established the basis empirical data. The effects various heat treatments salt quenched and oil quenched materials are compared. homogeneity developed incomplete hardening during the quench. The effect drawing temperature the Izod impact resistance and Rockwell hardness for oil quenched and salt quenched SAE X4130 steel shown Fig. This graph shows the rapidity with which the tough- ness increases when the hardness tensile strength this low alloy steel decreased. This data may used design determine what heat treatment any the steels should given order obtain suitably tough impact resistant material for particular use. The fact that temperature 500 deg. too high properly salt quench X4130 material shown this graph. Fig. shows the effect drawing temperatures hardness and im- pact resistance SAE 4140 steel. The oil quenched steel harder but not tough salt quenched steel. There only slight variation spread Rockwell and impact re- sistance between values attained for salt quenched and oil quenched ma- terial. The hardness and impact resistance values X4340 are nearly identical for salt quenched and oil quenched specimens that were drawn the same temperatures. This fact shown Fig. The salt quenched specimens have slightly better im- pact resistance values quenched specimens. The values the control specimens the table reveal some very in- teresting facts. SAE X4130 steel that was drawn 600 deg. has practi- cally the same Rockwell hardness the control specimen (not drawn) but has lower impact resistance values. This would indicate that possible obtain better steel the “as quenched” condition than drawing hr. 600 deg. some cases. SAE 4140 and X4340 steels drawn 600 deg. have greater impact resistance and lower hardness than control specimens these respective materials. This line with the statement that drawing will lower the hardness and increase the impact re- sistance low alloy steels. The fact that 4140 and X4340 salt quenched specimens, drawn 600 deg. F., have lower impact resistance values than the “as quenched” control specimens, indicates that drawing