The Iron Age 1945-04-05: Vol 155 Iss 14

and Advertising Offices 100 East 42nd St., New York 17, U.S.A. President and Editorial Director BAUR Vice-President General Manager LEONARD Assistant General Manager HAYES Advertising Manager JOHNSON, Manager Reader Service and Market Research BAUR, Production Manager CLEARY, Technical Research and Promotion Manager Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd St. ROBERT BLAIR GIBBS Cleveland Pittsburgh 428 Park Bidg. HOTTENSTEIN Chicago 1134 Otis PEIRCE LEWIS WARREN Detroit Hartford Conn. 1016 Guardian Bidg. HERMA 7310 Woodward Ave. Box Philadelphia Chilton Bidg. 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 VAN DEVENTER BAUR Vice-President FAHRENDORF Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE HARRY DUFFY CHARLES HEALE WILLIAM VALLAR, Asst. Treas. Member Audit Bureau Circulation Member, Associated Business Papers Vice-President Vice-President Vice-President Vice-President the Industrial Arts Index. Pub- lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single Copy, cents. ° ° ° Copyright 1945, Chilten Company AGE Vol. 155, No. Editorial When Dreams Come True Technical Articles Spot Welding Magnesium Conveyorized Finishing Equipment Ampcoloy Announces Continuous Cast Cost Welded Sequence Control for Automatic Riveting Rigid Sheets Made Roll Embossing. Electrode Coating Unit has Novel Features Shot Peening (Part Features News Front Assembly Line Washington Personals and This Industrial News News and Markets Canadian Aluminum Plant Largest Metal Equipment Committee Formed Crosley Stay Auto Light Metal Heatings Continued. Pehrson Sees Shifting Ore Machine Tool Market Developments. Nonferrous Metals News and Iron and Steel Scrap News and Prices Comparison Prices Week and Year. Finished Iron and Warehouse, Semi-Finished, Steel Prices Steel Pipe, Tubing, Wire Products, Prices Pig Iron and Coke Stainless Steel and Ferroalloy Prices Index Advertisers al April 1945 122 126 134 150 152. 153 156 158-159 160-161 162-163 164-165 166 244 I71 | | . | T. | | 96 101 q 4 } ° ° ° | | | 113 | ABE | | | | i | Ls | Each alloy shipment personally inspected and tagged part rigid quality control system, which call the Ryerson Certified Steel Plan. This plan covers: selection the individual heats alloy steel, the testing sampies from each heat, the positive identification every alloy bar with stamped heat symbol and painted color markings (or with metal tags), and Ryerson Alloy Steel which sent with each ship- ment. This report shows complete test informa- tion for the particular heat steel used filling your order. contains: chemical analysis, rec- ommended working temperatures, the Jominy hardenability results, and interpretation How Ryerson Assures Alloy Steel Quality physical properties for and inch rounds quenched and drawn 1000°, 1100° and 1200° The report serves positive identification, check quality and guide satisfactory heat treatment. The Ryerson Inspection Tag symbolizes the final culmination our quality controls, because fulfillment every specification your order. This the Ryerson way making sure that you get the right steel. Ryerson alloys all receive the same systematic care. Call Ryerson for alloy steels, for any other type steel, and assured uniform quality and prompt action. STEEL Joseph Ryerson Son, Inc., Steel-Service Plants: Chicago, Milwaukee, Detroit, St. Cincinnati, Cleveland, Pittsburgh, Philadelphia, Buffalo, New York, Boston. 4 ¥ ESTABLISHED April 1945 VAN DEVENTER and Editorial Directer BAUR and Generol Manager ° ° ° Editorial Stoff ° ° ° WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Assistants Editors DAVIS News and Technical Editors LLOYD Pittsburgh 428 Park POST Chicago 1134 MOFFETT DONALD BROWNE EUGENE HARDY National Press Bidg. LLOYD Guardian Bidg. BRAMS 7310 Woodward OSGOOD MURDOCK San Francisco Market St. Correspondents McINTOSH DEAN FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louls JAMES DOUGLAS é When Dreams Come True over two years ago dreamed dream but that time could not forsee its materialization. However, since the edi- torial page The Iron Age not bound, like the remainder this journal, the purely objective disclosure facts, dream slipped into type March 18, 1943, under the title Economics.” The thought expressed was that management and labor our mod- ern economic world really have many more things common upon which they can cooperate for mutual benefit than points difference. Objectives, you please, that can only reached working together and which cannot reached fighting each other. Labor, for example, profits does management from more goods for more people lower prices. reduction the price housing food shoes automobiles means much more the man earning $30 $40 per week than the man earning ten times that much. thou- sand times more shoes and automobile tires are worn out the process stores than walking riding executive offices stock-holders’ meetings. management and labor both have stake, and most important one, cost reduction and increasing productivity. There other really practical way than these get that increased purchasing power that shall soon looking for and that means more goods for more people and more jobs for them. Although seemingly indirect factor, but none the less most direct influence, bearing this the matter economy government ex- pressed tax reduction. Individual income taxes are now great, not greater, total volume than are corporate taxes. And since per cent more national income the individual income wage earners, evident that American labor has much greater stake postwar gov- ernment economies than has ownership. Ownership represented management really working together common orchard. The fruit that raises the fruit enterprise. That fruit the sole means economic sustenance for all parties and only point difference between them should the relative share each. Unfortunately this fundamental truth overlooked great many people both management and labor. For the majority our strikes and labor disputes are not over wages but over inconsequential and easily rectifiable causes men open mind and good will. These things, believe, are caused lack understanding fundamental economics many our managers and our labor leaders. For the long run both need more apples from the orchard. dream two years ago put into type this page, said: “Our future managers and labor leaders alike will largely college graduates. would good thing they could school together, learn what the fundamentals are which they can and should agree and how settle that which they cannot agree with the least pos- sible friction.” augurs well for our postwar labor relations outlook that such uni- versities Cornell and Harvard have recently announced the formation courses designed for this very purpose. ay | | Inland Hi-Steel buckets, truck bodies, screens, chutes, etc., are giving many times the service obtained from other steels. HI-STEEL LASTS TIMES LONGER The facts behind this story lower main- tenance costs began six years ago when Inland Hi-Steel replaced mild steel for buckets, truck bodies, screens, and conveyors the tipple Maumee Collieries. The mine records indicate that mild steel failed every months, due the abrasive action the coal. The same records show that Inland Hi-Steel, with its high resistance abrasion this type service, has been use for over years without single replacement ... and that still going strong. After the first year, when the higher cost Inland Hi-Steel was paid through INLAN 48—THE IRON AGE, April 1945 savings, every ton coal that traveled down the chutes, through the screens and over the conveyors was handled less cost. Inland Hi-Steel not only abrasion and corrosion resistant, but its high- strength means weight saving well. doing many important war and peace jobs where these favorable characteristics mean savings time, labor and materials. Write for the Inland Hi-Steel Bulletin. Inland Steel Company, So. Dear- born Street, Chicago District Sales Offices: Cincinnati, Detroit, Indian- apolis, Kansas City, Milwaukee, New York, St. Louis, St. Paul. Mote and usil the: the and date News Donald Douglas, conservative aircraft builder, calling the nent solve the industry's problems. Behind his appeal the fact that harsh interpretation certain existing regulations might ruin any all the aircraft firms. Ohio employers this week faced dilemma wartime legislation permitting overtime work for women lapsed, and legislative delays prevented reinstatement. law limits the work week hours, when some women are actually working hours. The next issue Air Force, the official service will again scoop the nation's press, this time with announcement the existence the super long range version the Thunderbolt, and the performance fighter. Army Air Force officers, assigned prematurely contracts settlement work last fall, have been marking time while the War Department reconversion. VE-day cutbacks will send these men back work. British writers state that jet plane could arranged before the war ends fly across the ocean. Such design, with maximum fuel capacity, would admittedly not combat type conceived today. Recognition foremen's right organize the NLRB will touch off immediate organization drive Detroit, where the Foreman's Association America was active before the adverse court decision 1943. Broad insurance coverage for its member workers will asked for the Automobile Workers, CIO. The plan calls for the setting aside sum three per cent each worker's pay for social security fund. This three per cent would not deduction from pay envelopes, but would tribution management. The fund, however, would administered the union. Opposition this proposal, which will first introduced General Motors, will probably based wage stabilization since effect this would The Chesapeake Ohio Railway has asked WPB for permission build three coal burning locomotives type designed use combination steam, turbine and electric drive. present electrically driven locomotive powered steam turbine operation this country. Basic designs which have already been completed Baldwin call for the development 6000 hp., delivered from turbine generators for the electric motors which drive the wheels. The locomotive will capable running more than 100 miles hr. under full load with high sustained speeds even grades. Preparations are under way for restoration East Indian rubber plantations using all available military well civilian labor soon the territory occupied. Orders for buckets, possibly made aluminum, collect sap, are the number millions. Late wartime construction will warehouses for the display and disposal surplus goods. Contracts are now being let for this construction, localizing certain items their most favorable market areas. Pressure the postwar private plane field increasing Aeronca buys the rights spinproof craft, Piper announces its postwar single place model and four place family sedan, and William Stout, affiliated with the Consoli- organization, exhibits photos controllable wing plane new design which appears roadable type. The steelworker's union bargaining agent for employes plants the Aluminum Co. America has obtained shift differential increases place 15c hr. increase requested. The order retroactive May 1944. IRON AGE, April 1945 Optimum machine settings two types stored energy Spot Welding Magnesium Alloys welders have been worked out experimentally for various gages magnesium alloys. attempt improve shear strength values and consistency chemical precleaning technique has been developed that superior wire brushing many respects. The relative effectiveness chemical protective finishes applied after spot welding has also been studied. These latter two phases are covered the concluding part the article follow. PPLICATIONS magnesium designed take ad- vantage its light weight welding process which the additional weight welding rod not required de- sirable means fabrication. Spot welding rapid and requires neither welding rod nor flux, absence which reduces the possibility corrosion magnesium due inclusions. has long been known that magnesium alloys can spot welded. However, considering the possi- bility method fabrication for aircraft parts, was necessary de- termine existing stored energy type welding equipment ® KENNETH DORCAS Research Laboratory Analyst and SIMPSON Chief Chemist Consolidated Vultee Aircraft Corp. Fort Worth, Tex., Division would produce strong and uniform welds. this con- nection test strips several magne- sium alloys, vary- ing thicknesses, were welded with range control settings three dif- ferent spot welding machines deter- mine optimum operating conditions. Tests several methods chem- ical precleaning magnesium alloys were also conducted and the relative effectiveness each was compared with the others and with conventional mechanical precleaning. This was done with the aid surface re- sistance meter, based the premise that good spot welds and low sur- face electrical resistance hand hand. this means was pos- sible develop chemical preclean- ing process prepare magnesium alloys for spot welding men 0.020 gage AMC sium alloy welded Sciaky machine. right photomacro- graph the spot weld surface. superior certain respects me- chanical cleaning. Studies were also made the relative effectiveness recognized chemical chemical protective finishes after welding. The major portion the specimens tested were made from American Magnesium Co. alloys, particularly gages ranging from 0.0616 0.125 in. However, other alloys and AMC57S-H, and and Fs-la, the latter two produced Dow Chemical Co. Specimens for the spot weld tests consisted 1x4 in. sheets over- lapped in. and welded with single spot. typical spot weld test spec- imen shown Fig. All the strips were cleaned with brush before being welded except those specimens used later con- junction with the development the cleaner. The wire brush used for cleaning specimens was 0.003 in. stainless steel wire in. wheel operating 3450 r.p.m. The de- crease thickness the magnesium alloy sheet after the wire brush clean- ing was negligible when measured with micrometer. Three spot weld- ing machines were used this test: Sciaky type PMCO 2S16 and Taylor- Winfield, type AWH 363 and type HWR 345DT. These three machines are d.c. spot welders. The available settings the Sciaky type PMCO 2S16 machine were follows: Two steps—80 155 volt Cycle controls Charging delay time Recompression time poles Precompression, with without Pressure, constant variable Cylinders, determine the optimum cycle settings, number wire-brushed test strips were welded using various settings the time cycle control. While the time cycle control settings are not critical, their values affect the pressure and current settings. The following data represent the best machine settings tested for spot Shear strength, Shear strength, t ‘ wel Rec Pole Prec Cyli and was : an var Wit cept olt S Shear strength 100 120 140 160 Maximum relay current setting, amp. gth, Shear stren Maximum relay cyrrent Shear strength 180 200 140 160 Shear stren 160 180 Maximum relay current setting, amp. 180 200 220 240 260 Maximum relay current GAGE 200 220 240 260 2-5—Experimental data showing relation spot weld shear strengths maximum current relay settings Sciaky type PMCO 2S16 reactor machine various air pressures. The material all wire brushed AMC52S-H magnesium alloy the gages indicated. welding 0.016 0.040 in. gage AMC 52S-H, using in. electroaes: Charging delay, cycles .............. Recompression time, cycles ........... determine the optimum pressure and current settings for given gage alloy, the Sciaky spot weld machine was set for the best time cycle, and arbitrary air pressure was used. test welds were made varying the maximum current relay from value that was too low produce weld, excessive cur- rent that caused spits cracks. Within this range were values current that produced usable and ac- ceptable welds reasonable strength. This procedure was repeated for other values air pressure, three four air pressures being tried for each gage alloy. The air pressure per sq. in. These test specimens were then pulled Tinius Olson 2000- Ib. testing machine and their shear strengths plotted against max- imum current relay settings. The air pressure that permitted the greatest range current setting without causing excessive indentation was se- leeted the best use. ab Figs. the graphs for 0.016 0.064 in. gage AMC52S-H material welded the Sciaky ma- chines using in. electrodes. The lower portion the curves for low current settings given welds unreasonably weak welds not shown. The top the curves indi- cates the points where spitting and cracking occurred. Welds were also made using higher values current, but since such welds could not used, this portion the graphs was also omitted. The selection the best air press- ure was based using the highest pressure possible without causing ex- cessive indentation distortion the surface the alloy. The higher air pressures gave greater operating range current settings, and also tended reduce sticking and burn- ing. The recommended air pressure shown Table for each gage alloy and charted Fig. The available settings the Tay- lor-Winfield Hi-Wave capacity type stored energy machines were fol- lows: Type AWH 363C2 Voltage ....... 100 2700 volts Capacity ...... 600 1200 microfarads Variable but not calibrated Type HWR 345DT 100 2700 volts Variable but not calibrated The and in. diameter copper electrodes normally used weld aluminum alloys were used during TABLE Optimum Sciaky Machine Settings (Type PMCO Air Pressure In. Current Minimum Shear Strength-Lb. 0.064 gage material was weld the Sciaky machine without the formation cracks the fuse THE IRON AGE, April es ne np. 0.016 130 170 150 the zene. spot 0.020 ABOVE 6—Relation Sciaky machine settings gage wire- brushed AMC52S-H magnesium alloy. ° RIGHT 8—Data similar that plotted Fig. except that 0.050 Gage 1400 Shear strength 1600 0.060 0.070 Shear strength 1800 2200 2400 2600 Voltage 7—Experimental data showing relation spot weld shear strengths voltage settings Taylor-Winfield type HWR-345DT machine with 3240 capacity settings, welding wire-brushed 0.064 in. gage alloy. 1200 Voltage gage in. and machine capacity setting, 4320 mfd. this test. Unfortunately ready means were available form and maintain constant contour the sur- face the electrodes. This situation caused considerable difficulty mak- ing definite determinations. The air pressure was set arbitrary value and the voltage varied from too low value excessive value similar the method used the Sciaky machine. However, addi- tional series tests were made vary- ing the capacity settings. These test specimens were pulled for shear strength and their curves plotted Figs. and The curves for various capacity settings for the Taylor-Winfield ma- chines are not shown since varia- tion the capacity mainly shifts the voltage setting both contacts de- rectly affect the current strength. Hence Figs. and show the shear strength vs. voltage curves for one capacity only for each gage. Table gives the recommended settings taken from these curves manner similar those obtained Sciaky machine, using in. elec- trodes. Minimum Shear Strength The minimum shear strength for given gage was determined em- pirically inspecting the shear strength vs. current voltage curves. The minimum shear strength the lowest permitted value for produc- TABLE Optimam Settings for Taylor-Winfield Type HWR 345DT Machine Gage Alr Pressure AMC52S-H In. 0.064 0.081 52—THE IRON AGE, April 1945 Capacity Mfd. 3240 4080 Minimum Shear Strength-Lb. Voltage 1800-2000 668 2000-2200 1030 tion spot weld given gage and alloy. These values were determined backing away from the top the curves amp. for the Sciaky machine settings and 300 500 volts the Taylor-Winfield machine set- tings. These values should equiva- lent those given for magnesium alloys Specification 20011-C which covers the alloys. Table III summarizes the minimum shear strengths determined these tests. Some values for alloys other than AMC52S-H are given, al- though not all the gages for these alloys were available. Visual examination was made the surface the welds for excessive indentation, spits, cracks, existence burns the pickup electrode material the surface the but- ton. Microscopial examination was made the etched cross-sections the weld determine size and shape the fused zone and the existence interior cracks and inclusions. Figs. and show the photo- micrographs the etched cross-sec- tion the spot weld specimens. All these specimens were made with 800 pe: mé aff the est ing the ‘ 1G. 9—Photomicrographs etched sections AMC52S-H magnesium alloy spot welds made Sciaky machine. the recommended spot weld machine settings previously given Tables and II. should noted Fig. that the welds the 0.064 AMC52S-H alloy, made the Sciaky machine, were usually cracked within the fused zone, although they ap- peared sound the outside and had good shear strength. was for this reason that the 0.064 and 0.091 in. gage tests were made the Taylor- Winfield type HWR 345 machine. complete description the theory and practice spot welding cannot given here but mention should made the factors that determine the strength weld, namely: Current strength (2) Current dwell (current time cycles) (3) Pressure electrodes Contour electrode tip Surface resistance (6) Thickness material Electrical resistivity welded ma- terial (8) Heat conductivity welded material Heat conductivity electrode (10) Thermal coefficient expansion material For given gage given alloy, items through remain vari- ables. There are several factors that affect the current strength other than the current settings the machine: (1) Pressure (2) Electrode contour (3) Arm separation and distance elec- trodes from transformer was impossible record and establish exactly these effects dur- ing the tests. (Each individual opera- tor dresses the electrodes tip slightly different contour even the same type). Hence, the shear strength curves, Figs. 2-8, cannot duplicated exactly. However, the object was establish the best machine settings for spot welding magnesium alloys, these curves supply data establish IS. crographs etched sections AMC52S-H magnesium alloy spot welds. The cracks shown the 0.064 in. gage material welded the Sciaky ma- chine are typical. 2) ° the recommended pressures and min- imum shear strength. Any change the setup that affects the current strength will shift the curves the right left. The gen- eral practice using current voltage setting that just below that which causes spits cracks places the operation near the top the curves. often desirable express the spot weld machine settings terms actual electrode current and pressure. Such information cannot derived from the machine settings themselves due the dependency the current upon the factors listed above. Therefore, separate calibra- tion the machine must made. This was conducted the Sciaky ma- chine, shown below: Max Relay Current Electrode Electrode Setting, Current, Pressure, Amp. Amp. Lb./Sq.In. 100 20,900 24,000 150 25,900 24,900 200 30,250 24,000 100 19,800 30,0900 150 24,800 30,600 200 28,600 30,900 These values were obtained while welding 0.064 gage wire-brushed AMC52S-H alloy. (In the second and concluding part the article the authors will describe periments with large number chemi- cal cleaning agents before suitable one was developed that gave surface re- sistance magnesium comparable wire brushed specimens. TABLE Summary Spot Weld Minimum Shear Strengths, Pounds, Various Magnesium Alloys Spec. AM3S-0 20011-C** AM3S-H All these alloys were very easily welded except which was only with great difficulty. 20011-C covers all the alloys and therefore the minimums that expected THE IRON AGE, April 1945—53 and ned the aky olts set- iva- lum lum in loys sive rode Gage FS-la |AMC57S-H was 0.016 150 ence 0.081 500 202 with Conveyorized Equipment for Finishing Increased processing capacity for cleaning and finishing alum- inum, magnesium and steel parts amounting over 800,000 per week has been attained continuous overhead monorail con- veyor with appreciable saving space, manhours and material. ARLY instal- lation con- veyorized JANSSEN and WILLIAMS Material and Process Engineering Generally speak- ing steel parts are cadmium equipment for Department, zinc plated, cleaning and finish- North Aviation, Inc., parts ing many the Inglewood, Cal. are chemically parts that make the struc- ture finished airplane has con- tributed largely the ability the Inglewood Division North Ameri- Aviation, Inc., meet ever- increasing wartime production sched- ule—a schedule which recently ex- ceeded 550 P-51 Mustang fighter planes for one month. Much the tedious work that ordinarily per- formed aircraft factories lifting parts and out series process- ing tanks now taken care auto- matically after the parts are attached continuous overhead monorail conveyor. coated and painted and aluminum parts are painted with zine chromate primer protect them from corrosion. Careful preparation the surface the parts prior application the finish coatings necessary obtain satisfactory ad- hesion the protective film. But when over 800,000 parts per week must processed this becomes labor consuming job conventional procedures. increased processing capacity would needed avoid bottlenecks the processing department, industrial en- gineering made complete survey this department. When was shown that appreciable savings space, manhours and materials could ef- fected, three conveyorized cleaning machines—a mechanical trichlorethy- lene spray degreaser, spray chroma- tizer and stringer cleaning machine —were purchased. The general loca- tion these machines the depart- ment shown Fig. The degreaser selected was steam- heated Detrex vapor-spray-vapor de- IG. drawing processing de- partment showing general location equipment. LEFT 2—Conveyorized degreaser showing baskets parts enter- ing and leaving cleaning cham- ber. Hooks are in. apart and travel ft. per min. they ing cre Conv f 3—View ild conveyorized washing machine showing typical parts they leave the dry- ing Hooks in. apart. Conveyor travels ft. per min. boiling sump, (b) carried through chamber between series spray nozzles where they are sprayed with hot solvent and finally, (c) taken through final vapor rinse and then out. the parts are sent for cleaning only they are removed from the conveyor when they come out greaser with rated capacity 3000 the degreaser. they are lb. aluminum per hr. they are left the con- for cleaning precision machined carried onto the work prior inspection and for where they are removed heavy oil and grease from aluminum, the proper point and carried through steel and magnesium parts prior the appropriate sequence opera- the plating cycle chemical ment. The parts are wired, racked The conveyorized placed baskets and suspended two open top, dip type the overhead conveyor (see Fig. which had been using ap- When they enter the degreaser 650 gal. chlorinated are (a) lowered down through solvent per month. Though the new chlorethylene vapor phase above was immediately burdened THE IRON AGE, April 1945—55 de- | 4 with two three times the productive load capable being carried the two dip degreasers solvent consump- tion dropped less than 600 gal. per month. Spray Chromatizer The chromatizing machine selected was the Blakeslee gas fired, four tank, spray washer shown Fig. Parts attached the conveyor run- ning through this washer are auto- matically cleaned, passivated, dried, .painted, dried and returned min. the trucking area for transmittal the proper assembly department after inspection. This washing ma- chine replaced the conventional series four dip tanks and drying oven 56—THE IRON AGE, April 1945 used for chromatizing aluminum parts and the same general cycle opera- tions followed. However, the solu- tion concentrations and process times have been appreciably reduced shown the table. Actually has been found that sec. each the alkaline cleaner: and subsequent rinse spray sufficient remove ordinary soil, the lard oil and kerosene used the routers, and the soluble oil mixtures used the ma- chine shop. This due the vigor- ous mechanical cleaning action the sprays. Heavier materials such the oil used for heavy forming the drop hammers and the compounds used for deep drawing operations are removed vapor degreasing before 4—Dip primed drying The firewall the left around the primer dip tank the sec- ond two firewalls separating the tank from the gas fired spray washer. the parts are sent through the wash- ing machine. With regard the operation the unit, the parts are attached individu- ally batches hung racks hooks connected continuously moving overhead conveyor which car- ries them into the washer. Tanks the bottom the spray chambers 500 gal. capacity contain the process- ing solutions. Centrifugal pumps de- liver the solutions under ft. (maximum) head the spray nozzles set such manner that the parts are thoroughly sprayed from both sides, the bottom and down from above. Drain areas between the sprays permit the solutions drain back Stringer cleaning machine and trucks with typi- parts cleaned and passi- vated. line dip low mal hav tors stal trac bee! per: eft ner alls sh- the du- de- ft. arts oth into the reservoir tanks. Before the solutions are recycled they pass through double wire screens and sedi- ment chambers remove chips other materials that might plug the spray nozzles. The external sediment chamber tanks are equipped with ad- justable, constant level, float type, control valves and skimmer type over- flow troughs. Periodic additions chemicals are made indicated the results laboratory control analyses. Compressed air blows off the excess water from the parts they enter the gas heated drying chamber. dip the conveyor line outside the oven permits aluminum which are too long through the present primer dip tank removed after they have partly cooled. Anodiz- parts, small spotwelded assemblies, and magnesium parts dip primed may also attached the conveyor line this point. Parts left the conveyor line are carried through double firewall, and out primer dip tank, then around drying area (see Fig. The parts are al- lowed dry for min. before they are handled. The primer tank conventional many respects though some changes have been made. Two rotary agita- tors, driven hp. motors were in- stalled keep the primer mixed. Solvent losses, which first were ex- traordinarily high due heating re- sulting from constant agitation have been cut (1) installing refriger- ating unit which maintains the tem- perature the mixture just little above the maximum dewpoint the room and (2) using less volatile Comparison Immersion and Spray Chromatizing Cycles Concentration and Temperature Operation and Solution Dip Tank Mild Alkaline Cleaner....| 4-6 oz./gal. 160-170° 160-170° 6-8 120-140° 160-170° Hot Water Rinse Hot Water Rinse Hot Air Dry and somewhat slower drying thinner instead the standard AN-T-8 to- luene substitute thinner. Due space limitations the chro- matizing machine had built the shape and fitted into area approximately ft. instead being laid out straight line. For this reason was necessary purchase the third item equipment —the stringer cleaning machine—to clean and chromatize stringers, long- erons, spars, which were too long around the corners the shaped spray chromatizer. The string- cleaner quite similar principle the larger spray washer described above, except belt conveyor used. steam heated, and there drying chamber. The long rolled extruded parts are placed the belt which carries them through the spray Immersion Time Min. Spray Time Spray Sec. 6-8 150-170° 150-170° 4-6 140-160° 150-170° 275-300° 180 required chambers. When they come out they are removed, stacked end until dry, then spray painted. Conveyorized equipment for clean- ing and finishing detail parts has proved very successful this plant— successful that another larger con- veyorized washing machine has been ordered. Also, manually controlled overhead conveyors are installed for straight line processing mag- nesium parts dichromate treated and bare (not clad) aluminum parts which must anodized. Although conveyorized plating installations the North American Dallas and Kan- sas City plants have functioned very satisfactorily, the nature produc- tion Inglewood such that use automatic semi-automatic equip- ment for plating steel parts can not economically justified present. Ampco Announces Continuous Cast Bronzes machined used as-cast, has been an- nounced Ampco Metal, Inc., Mil- waukee. the name the process implies, the rod produced the continuous withdrawal metal from the bottom casting crucible. The metal solidified leaves the crucible and passes through suitable cooled die closely held dimensions. guid- driving rolls traveling cut- off device which engages proper in- tervals yield sound rods good surface, uniform diameter and even length. Dirt and drosses, being light, not enter the solidifying rod ac- cording the company gases, al- ways present, are eliminated upwards and the molten bath presents steady hydrostatic head prevent the formation shrinkage cavities. proof inherent soundness degree hitherto not consistent com- mercially, the density the material produced for practical purposes equal the theoretical density. Metallographically, the extremely uniform—lead other sec- ondary constituents being uniformly dispersed finely divided state across the entire section. This readily seen photomicrographs. the present time the following bronzes are available continuous cast rod that meets the chemical and physical properties the specifica- tion indicated. AMS 4845B SAE 62—Ampcoloy 742 tin bronze. 342, high lead bronze. SAE 660 Ampcoloy 382, bearing bronze. According Ampco, the benefits expected from the use this ma- terial include: (a) Improved quality all produc- tion. The practically complete elimination scrap because metal faults. (b) Faster production—adaptable semi fully automatic rather than hand chucking machines. (c) Smaller volume purchase, receive and handle. (d) Less scrap accumulation, cleaner shop, more space. (e) Manpower savings—for all rea- sons above. (f) Better tool life—no sand sur- face, segregations internally. Lower power production costs— many cases drastic. (g) THE IRON AGE, April 1945—57 | nger shine typi- assi- Williams the Cooper Bes- semer Corp. the compari- son costs construction using and weldments leaves such unfavorable impression weld- ing that the author feels that the ex- perience others with the same similar designs should presented. was stated this article that, “the best cost finish machined weld- ments proved nearly twice cast- ing costs.” However, careful analysis the engineering principles involved the production the items marked discrepancies which disprove the claims made. order not seem prejudiced, was decided make survey among leading producers heavy machin- ery the type discussed the above-mentioned article. The results showed such overwhelming repu- diation the cost comparisons the Williams’ article that some engineer- authorities were surprised learn that such apparent lack open-mindedness for welding existed these days pro- gressive fabricating techniques. The 58—THE IRON AGE, April 1948 welded steel bedplate new diesel engine which has double the power yet larger than the cast iron unit replaces motorship. simplicity joining means arc welding must kept continually mind. When this is.done the de- signing and breakdown for fabricat- ing can planned that mini- mum welding and handling will necessary. From the conclusions presented the article question, one logical assumption that full advantage the freedom design welded con- struction was not taken although this tremendous advantage one the inherent characteristics the weld- ing process. While the author “progress welding technology and design has been ‘effective’ that machinery can afford neglect what going that field,” apparently attempts con- vey impression that design for welding difficult. Whether this stems from lack understanding the relative simplicity welded design whether due his long association with his company’s large foundries that require large volume casting work assure profitable operation, largely left the reader’s imagination. CONLEY Consulting Engineer Lincoln Electric Co., Cleveland But let look the comparisons presented the article and weigh them with the conclusions reached prominent engineering authorities. the first place, Mr. Williams im- plies that heavy machinery parts, least those discussed his article, are designed for use only the basis cost limited production. Engi- neering significance reaches much deeper than this, even though the diesel engine items used examples the author were design that could apparently substituted, one for the other, regardless whether they were cast welded construc- tien. such was the case, those re- sponsible obviously did not use the proper designing approach. The proper designing approach welded construction does not involve attempt duplicate the former cast design. Full advantage the inherent freedom the welding piocess utilized fabricating the item from steel plate, bars, angles, channels and other structural shapes. The redesign may call for various combinations metals and alloys and possibly include pressed steel parts steel castings meet indi- vidual stress and service specifica- tions. Even though Mr. Williams claims that his casting comparisons were ob- tained from “outside firms who had won reputation for ingenuity de- sign and efficiency the production welded structures,” well his own company, his statement that the “weldments proved nearly twice casting costs” appears ridiculous the light results obtained from the survey just completed. The Cooper-Bessemer data for the engine block for 1000-hp. diesel repeated here for comparison with those follow: Cast (Meehanite) Finished weight, ....... 10,620 11,442 Production rate per month.. Finished cost, each ......... $1,774 Now analyzing this weldment basis the experience those con- sulted the survey and making esti- mates according the best welding Cost Welded mak as tha tur ané | 4 leq Structures Compared With practice, the following obtained very similar types machines and on Ww Gea Ges Ge é = = rebuttal the article, “Cost Meehanite Castings vs. Welded Structures," Williams, Cooper-Bessemer Corp., appeared the May 18, 1944, issue THE IRON AGE. Finished weight per piece, order disprove the statement that certain finish machined weld- Material cost per piece ..... cost twice much finished castings, Mr. Conley sum- marizes the results informal survey welding fabricators made his company both here and abroad. detailed study the article, mately the same weight our own im- ‘Meehanite Castings vs. and have the following cost piece and machining ..... $540 was made and the cost comparison. These parts are just ticle, Total cost per piece including comparisons were analyzed. There about complicated weld and are basis $1,952 some inconsistencies also manufactured small quanti- Engi- fair comparison the cost the cost meehanite castings ties. much the pattern should deducted, pletely machined. “The following costs are comprised the making the cast block equal $1,602 “So far the cost welded con- material cost, hours, labor, and nples against $1,120 for the welded struc- struction concerned, compared and not include any ma- that ture. the parts similar parts approxi- the finished welded struc- Not only was there discrepancy ether $5755 comparative welding Cost Welding Diesel Engine Components costs, but additional weight saving 3442 lb. was indicated through Weight, Hours Cost Cost the proper application welded rede- engine revolving frame 14,115 252.3 $1,082.37 $0.077 sign. This makes hard under- Manifold separator 188 6.4 20.57 0.109 volve much six times higher per item gear case cover 547 46.10 0.085 than these conservative figures. One the prominent manufac- the turers similar types heavy ma- chinery submitted _the following apes. analysis which typical those re- ported the survey: steel indi- laims ob- had de- his the twice the ABOVE the 3—Weld designed manifold which re- sulted per cent cost reduction due with simplifications. 11,442 RIGHT 2—One the main columns, built entirely arc welded steel for 4000 hp. diesel engine recently completed Eng- THE IRON AGE, April 1945—59 tures. The machining was omitted because difficulty ascertaining the amount machining the pieces discussed the article.” Note that the cost per pound parts for welded fabrication the above group comparable items averages only $0.097, while the price per pound the machined welded parts listed the article under dis- cussion runs high $2.63, un- heard figure until its appearance the article. [For the engine block and base, the total machined cost $0.60 per lb. Ed.] Further evidence the fallacy the claims made the author the article his reference “ruinously expensive failures” certain types steel engine frames welded de- sign. bases his statement in- formation from individual Brit- ish naval affairs who said have found that steel weldments under se- vere battle conditions, are sometimes thrown out line that they can- not salvaged. This evidently attempt subordinate the greater known strength rolled steel over cast iron shown the accompany- ing table relative comparisons. may argued that cast iron qualities may improved, that the unit stresses may changed; that other casting materials may used. this done, the cost per pound increased and the increased saving due the weight reduction largely offset. Mechanical Properties Compared For special cast iron the American Society for Metals Handbook gives the tensile stress 35,000-50,000 Ib. per sq. in. and the compressive strength 135,000-175,000 Ib. per sq. 4—Ease assembly and welding produced per cent cost saving production this engine oil pan. in. The American Society for Testing groups with values for tensile strength from 20,000 60,000 per sq. in. The higher strength irons are 5—Special welded sub-base for diesel engine designed that ordi- narily unused space could utilized without increasing overall dimensions structure. premium materials the case Meehanite. Brady’s Materials book gives values for this latter ma-- terial 35,000-55,000 Ib. per sq. in. for tensile strength and 135,000-. 175,000 per sq. in. for compression.. Bulletin No. the Research Institute America, Inc., gives values for type Meehanite follows: tensile strength 56,300 per sq. in., yield point 47,200 lb. per sq. in., proportional limit 21,600 Ib. per sq. in., and modulus 21,000,000 per sq. in. com- parison with structural steel values would indicate relatively high design stresses but must remem- bered that Meehanite still cast. iron, that higher factors safety must used shown the giving average values for cast iron. The statement concerning “ruin- ously expensive failures” was made- despite the fact that there are thou- sands welded diesel frames isfactory service, many which have withstood repeated that these structures survived such conditions much better because their welded construction. Some the responses the Lin- coln survey included “heavy” ery manufacturers such diesel engine builder who reported construc-. tion welded diesel engine re- placement which doubled the power the vessel into which was in- stalled, yet required more space than the original unit. The report said part, “Construction en- gine having high ratio power size has been made possible im- proved design employing steel and electric welding. Major parts such bedplate and columns, well scavenging air main, crankcase cov- H ers imu | eee : gin act i Ww é 60—THE IRON AGE, April 1945 ‘for water ers and plates and exhaust pipe, are all built welded steel plate. The use arc welded steel provided max- imum strength and rigidity per min- imum size members and minimum pound weight. This advantage en- abled obtain structure double the capacity possible with suitable form cast iron construction.” Views this redesigned diesel en- gine are shown Figs. and Other welded engine parts similar those discussed the Williams article are illustrated additional accompanying photos. Fig. shows manifold consisting one inner casing in. diameter and in. long; one outer casing in. diame- ter and in. long; two cast steel flanges, threaded inside for in. pipe; four pieces fabricated square tubing; four cast steel elbows milled and drilled fit exhaust port cylin- der studs; and two cast steel bases inlet and outlet ports. Study production procedure dis- closed means simplification which permitted per cent reduction cost, that is, from $20.75 $11. Fig. illustrates oil pan rede- signed for welding which resulted cost saving per cent due speed and efficiency assembly. Another typical example the free- dom welded design shown the all welded diesel subbase, (Fig. which was welded three sections weighing total 6330 Accepted Design Factors for Rolled Steel and Cast Material Ultimate Values Ib. per sq. in. Cast iron......... Rolled Material Safety Factors Rolled steel....... Material Working Values Compression Ib. per sq. in. Rolled Material Working Values Tension Rolled Compression Tension 100,000 30,000 60,000 60,000 Load Steady Varying Shock Load Steady Varying Shock 15,000 9,000 4,500 20,000 15,000 7,500 Load Steady Varying Shock 2,000 1,500 20,000 15,000 7,500 Although many other types “heavy” machinery parts were cov- ered the survey, space does not permit review the entire field. Thousands heavy machine struc- tures, however, are being turned out constantly and every indication shows that more and more are being rede- signed for welding. Thus, manufac- turers are continually showing fast growing preference for industrial de- signs the type made possible welding which possess qualities such speedier fabrication, safety and utility and economy which surpass the traditional designs they replace. ° ° ° HAT believed the largest mechanical, two hous- ing press brake the world was recently built for the American Rolling Co., Middletown, Ohio, the Cincinnati Shaper Co. Capable exerting pres- sure 1000 tons, the machine will bend cold plate #t. long in. thick shown the illustration. The machine has clear distance ft. between housings and overall die sur- face ft. their making, each the four main members required the full capacity Luken Steel Co.'s 200 in. plate mill, the largest the world. Housings are made in. plate and the ram and bed in. plate. obtain the ft. length the latter, wing extensions were arc welded each end the main plates. motor drives the brake, which weighs approximately 250,000 “ od THE IRON AGE, April in. ion.. nite om- em- ‘ety ible- ‘on. ave ttle ord uch re- in- ace: ort en- im- P, xX; Xo Bo B, B; A2 R, Y, Line switch coils switch Repeat Pressure switch WIRING CONTROL Pressure switch \ supply Pressure regulator supply valve No.2 SCHEMATIC DIAGRAM electronic sequence control unit for automatic riveting has been developed Consolidated Vultee Aircraft Corporation, San Diego, California, for the purpose increasing the efficiency Model 2002 Erco riveters. Before this unit was developed, was necessary for Model 2002 ma- chine operators control complicated flush riveting processes means foot pedals; and, because the speed and accuracy the individual ma- chine depended entirely upon the alertness and good judgment the operator, mistakes were occasionally made—causing excessive losses time and materials, and necessitating the premature replacement ma- chine parts. With the new electronic sequence control unit, the Erco machine oper- ator required depress only 42—THE IRON AGE, April 1945 single lever; thereafter, the entire punching and riveting sequence ac- complished without human assistance. Time studies have revealed that this produces per cent increase effi- ciency and parts savings more than per cent for the Model 2002 Erco machines. Physically, the new unit resembles small radio set. governs the operations Erco riveter simply actuating series electrical cir- cuits suitable sequence. The electrical circuits turn actuate the various parts the machine the required order. With reference the accompany- ing schematic diagram, events take place the control unit and riveter follows: (1) The foot switch closed the operator and relay energized, (2) Closing contacts P-1 energizes the solenoid, opening Ross Valve No. (3) Air entering auxiliary cylin- Auxiliary cylinder cylinder ° ° THESE schematic diagrams indi- cate the functions the elec- tronic sequence control unit connection with Model 2002 Erco riveter. ° ° ° der No. actuates the shift mechanism moving the die button into the punching posi- tion, locking the punch, shift- ing the piston stop block un- der the main piston, and opening the control valve. (4) Air entering the main cylin- der drives the plunger down into the die bottom, whence tacting the material and forc- ing the die over the punch until halted the piston stop block. (5) When air pressure the main cylinder increases sufficiently, pressure switch closes. (6) Closing pressure switch en- ergizes relay closing con- tacts B-1 and B-3. (7) Closing contacts B-1 energizes relay (8) Energizing relay opens con- tacts X-1. (9) Opening contacts X-1 de-ener- gizes relay = Control for Automatic (10) (11) (12) Opening contacts de-en- ergizes the solenoid Ross Valve No. and allows air exhaust from auxiliary cylin- der No. When the air pressure aux- iliary cylinder No. re- duced, the spring the main cylinder contr