The Iron Age 1945-05-17: Vol 155 Iss 20

VAN DEVENTER President and Editorial 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 Executive Offices Chestnut and Sts. Philadelphia 39, Pa., Editorial and Advertising Offices East 42nd St., New York 17, N.Y., U.S.A. ° ° ° Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd Cleveland Pittsburgh 4016 Guardian Bidg. Pork Bid 1134 Otis RAYMOND KAY Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY (Incorporated) OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH Vice-President €VERIT TERHUNE Vice-President VAN DEVENTER Vice-President BAUR Vice-President FAHRENDORF Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE HARRY DUFFY BUZBY THOMAS KANE CHARLES HEALE WILLIAM VALLAR, Asst. Treas. Member Audit Circulation Member, Associated Business Papers tadexed the Industrial Arts Index. Pub- fished every Thursday. Subscription Price America, South America and Possessi ions, $8; Foreign, $15 year. Single cents. Vol. 155, No. IRON AGE Editorial Has Been Will Technical Articles Aluminum Press Forgings Chevrolet Power Tool Burrs Edges Salvaging and Process Control With the Particle Size Analysis Iron Flush Head Rivet Gives Seal New Equipment Features News Front Assembly Line Washington Personals and Obituaries Dear Editor This Industrial Week News Industry News and Markets Geneva Plant Analyzed ..... Light Metals Discussion West Prefabricated Houses England WPB Revises M-21 ............. Postwar Construction Demand More Warehouse Officers Canada Moves Towards Reconversion Machine Tool Market Developments Nonferrous Metals News and Prices Iron and Steel Scrap News and Prices Comparisons Prices Week and Year Finished Iron and Steel Warehouse, Semi-Finished, Steel Steel Pipe, Tubing, Wire Products, Prices Pig Iron and Coke Prices .......... Stainless Steel and Ferroalloy Prices Index Advertisers May 17, 1945 101 110 118 130 136 142 154 156-7 158-9 160 162-3 164-5 166-7 170 199 $2.80 $2.90 $1.50 $1.10 60c. $2.30 ° ° ° ° the Cure? Ever feel like the fellow above—as though have walk sideways keep from flying? And all because difficulty get- ting enough certain kind steel tide you over. matter fact these hectic times this frantic condition not always imme- diately curable. how much relief can often secured However, it’s amazing matter minutes calling Ryerson. not infallible course. For, though are shipping tremendous ton- nages war plants and critical industries from Ryerson plants—our stocks JOSEPH RYERSON SON, Steel-Service Plants at: Chicago, Milwaukee, Detroit, St. Louis, Cincinnati, Cleveland, Pittsburgh, Philadelphia, Buffalo, New York, Boston 44—THE IRON AGE, May 1945 are not always balanced from size stand- point. But our stocks are still the nation’s larg- est. Our personnel highly trained and experienced. Our technical staff excep- tionally skilled. And all during our 103 years business, we’ve been meeting and overcoming critical you find yourself even remotely approaching the condition the harassed buyer above, remember this: Phone Ryer- son—and from our end the telephone everything within our power take care you. INC. ESTABLISHED 1855 May 1945 VAN DEVENTER President and Editorial Director BAUR Vice-President and General Manager Editorial Staff Technical Editor ........ OLIVER Commercial Editor..T. CAMPBELL Associate Editors WINTERS JACK HIGHT ALBIN JOHN ANTHONY BARMASEL Editorial Assistants MUNZER O'CONNOR MILLER HANSEN DAVIS Regional and Technical Editors LLOYD Pittsburgh 428 Park POST Chicago 1134 Otis 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 Louis JAMES DOUGLAS Seattle Has Been Will Be? that the tumult and the shouting have subsided and the Pacific becomes the remaining theatre action, well for moment look both forward. profit life from what and from what learn doing. One the big lessons that should learn from our experiences since Pearl Harbor the value disregarding precedents. Both the field battle and our war industries home, precedent has received beating that has left punch drunk. shall have less respect for the future, which well, because precedent largely the refuge those who are either too lazy too unimaginative produce new ideas. This war has differed from others not only because its severity but also the production and acceptance new ideas. Particularly perhaps the acceptance and use them military strategists who heretofore had apparently learned their tactics from the battle Gettysburg and the siege Richmond. During World War for example, one would troubled recal new weapons other than the depth-bomb and the tank, the latter accepted for use with considerable reluctance, even though precedent had been established for the form the Trojan horse. this war the number new devices devoted destruction legion. Tanks have been taught swim, projectiles have been taught fly and instruments have been taught think, plan and perform. Back home, our manufacturing plants and mills, respect for precedent has been equally lacking. sooner had the need become manifest for something that had not previously existed than the chal- lenge was met men science and industry and that something was brought forth. every field effort, from the production raw materials the variegated thousands thousands finished products, new ideas have been injected and progress made applying them more quickly and broadly and more successfully than any other period our history. The ability these things was not new-born. was there begin with, otherwise they would not have been done. could have done them before had the urge been sufficient. But took the war make America raise its sights. this fact indeed significant. means that have never before known used our strength. American industry, true, world champion, but may have won that title with its punches pulled. Knowing now what have been able do, even though yet know not all that can do, there excuse for permit the past pace our future. “has been” will always “has been” even what was done had been great accomplishment. And who wants “has been”? learn our lesson from experience, exile precedent measure performance and raise our sights, American industry can begin exercise its full measure strength during the coming years and lift all | 4 figs SCHIEN a Safe Footing for Navy Gunners Inland 4-Way Floor Plate gives maximum traction all four directions. Whether board ship, factories, public buildings, operating decks mobile equipment, Inland 4-Way Floor Plate gives safe and sure traction for feet and wheels. Made rolled carbon steel, Inland 4-Way Floor Plate has great structural strength and long wearing quality. This practical, 4-Way Safety pattern has dirt-catching ‘pockets corners. Liquids drain freely from 4-Way Floor Plate, permitting washing and drainage any direction making easy sweep and keep clean. Write for bocklet Inland 4-Way Floor Plate—the safest and most permanent type flooring. Bars Ficor Plate Piling Plates Rails Reinforcing Bars Sheets Strip Structurals Tin Plate Track Accessories INLAND STEEL COMPANY South Dearborn Street, Chicago Illinois Sales Offices: Cincinnati, Detroit, Indianapolis, Kansas City, Milwaukee, New York, St. St. Paul INLAND FLOOR PLA’ ~~. H News May 15, 1945 approval limited civilian plane production using surplus men and ma- chines finds the nation's aircraft firms tight-lipped the automotive Aircraft men are unwilling venture guesses delivery dates most them have firm commitments for their first production, and therefore have nothing gain optimistic predictions. Meanwhile, the British aircraft industry smarting under the fact that the allocation war transport responsibility the United States giving thé postwar business, both aircraft sales and air transport. General Somervell's confirmation plan for landing troops the China coast develops some minds parallel situation that cracking "Festung Europa". Japan holding force the major ports but other areas are thought relatively unguarded. Result that some sources predict use "prefabri- cated" harbors once again. Geneva Steel over the hump its coke problems. Yield from coal per cent, considered good basis type coal used. The plant needs more coal but output the mines still below total requirements. Reports that Geneva Steel's blast furnaces cannot hit capacity are Actual figures show one furnace's record 1059 tons one day while the other two furnaces have hit close 1000 tons day. Rated capacity all furnaces 1100 tons day. CMP July will probably preceded the green light for automobile production, according Henry Nelson, WPB industry reconversion coordinator. The approval will take the form weighted unit quotas, permitting each manufacturer the equivalent about per cent year's normal duction. Although little has been said about previously, Nelson states that version assistance for other industries available similar that provided for the automotive industry, whether not one the for which tor being named. The automotive industry, whose AA-3 priority machine tools was conflicting with similar rating held the Army and Navy, has wangled AA-2X, which will supersede the Army and Navy rating for tools. There still indication just how the auto makers are get delivery sheet steel this year, although there discussion the allocation certain percentage sheet production automobile production. ceiling price policy announced OPA sets system for justing costs account for increased war costs, but reflects over ali the agency's determination hold the line 1942 prices. New models are expected difficult price. manufacturer may have calculate increase factor old model, and then figure the increased decreased amount labor and materials get ceiling. The broad recommendations the House Special Committee Postwar Economic Policy and Planning for economic cooperation include not only tariff reductions but also limiting import quotas, export subsidies, exchange controls, and "other devices". The committee estimated that postwar private foreign investments might reach $2,000,000,000 per year. The Army has cancelled contract with Ford Richmond, Calif., under which the plant has been assembling 1,000 jeeps month since October, 1941. Productipn will probably end July Plans for Kaiser Homes "sparkplug the American Economy back normal" for two three bedrooms and will individually styled, contrast recent government projects. Approximately tons steel are required for each two bedroom house. 4 | a q ¢ q * ¥ iad 4 ¥ » | < aluminum heads for the Pratt Whitney radial air cooled engine are now being turned out volume Anderson, Ind., feed Chevrolet’s assembly while, however, looked Chev- rolet-Anderson would another DPC ghost plant—part the country’s ex- cess government owned aluminum fabricating plants. Originally this plant was built and equipped specifi- for forging Wright aluminum cylinder heads, but soon after the last machine was installed the Wright contract was canceled. the in- terim, Chevrolet took number other short contracts limber the equipment and gain experience aluminum forging, art new automotive forgemen. When Chevrolet swung into pro- with forged heads was natural that Anderson would supply the require- ments for the Tonawanda plant where engines have been made subcontract basis for several years. Since this decision was reached, other old buildings Anderson have been converted and equipped machine these heads well forge them, although the original plan for Ander- son contemplated only the forging operations. Because technical reasons dis- cussed later, was decided equip this plant with forging presses both the hydraulic and mechanical type well upsetters. Inasmuch available methods large extent, the facili- ties will first described before launching into discussion the methods employed make one the practice jobs well the cylinder heads. The principal press equip- ment comprises two 2000 ton HPM hydraulic presses, four 4000 ton Clearing mechanical presses and two Ajax in. upsetters, besides num- ber Bliss No. 8-60 trim presses. The equipment was laid out form 48—THE IRON AGE, May 17, 1945 Aluminum Press Forgings Chevrolet Manufacture forged aluminum aircraft engine cylinder heads the Chevrolet-Anderson plant exemplifies some the techniques press forging large components. Some the practices were worked out aircraft parts while awaiting the go-ahead the job for which heavy press equipment was nstalled. FRANK OLIVER two parallel lines, one for front heads, the other for rear heads double row radial engine. Press Equipment Cogging and preblocking opera- tions Anderson are performed the 2000 ton hydraulic presses oper- ating parallel, Fig. These HPM presses are actuated four self-con- tained hydraulic radial pumps driven pairs two 400 hp. motors and de- livering 185 g.p.m. oil each. With the safety valve set 2950 per sq. in., total pressure 2450 tons applied the in. diameter ram. Frames are tied together with four preloaded tie rods. Ram speed light 120 in. per min. and under full pressure, in. There are valves the hydraulic circuit, reversal the ram being effected reversing the delivery the pumps, obtained changing the eccentricity the pump plungers relation the radial pump cylinders. These units were especially designed for aluminum forgings which should worked with comparatively rapid pressing speed and long working stroke. sepa- rate motor driven pump the base supplies power for hydraulic knock- out, initiated cam microswitch the ram tripping solenoid valve. Each press served Surface Combustion continuous heated furnace, fired natural gas. They are capable heating 6000 Ib. billets forgings per hr. about heads per hr. Since the four Clearing mechanical presses installed Anderson are the only ones their size and capacity ever built, description their main features should also the first place, these 4000 ton presses, Fig. were designed specifi- cally for forging aluminum aircraft engine cylinder heads. The welded steel frame, the main bearing con- struction, the lubrication system and the hydraulic clutch design all pre- sented design problems for which the manufacturer could find little prece- dent. The welded steel frame, consisting bed, crown and uprights, held together four in. diameter tie rods which are preloaded 8000 tons, twice the nominal capacity the press. The main bearings are in. diameter, supporting in. diameter eccentric which has stroke in. Drive 200 hp. slip ring motor and V-belts through hy- draulic clutch. Normal speed strokes per min., although operation intermittent since, most forgings are completed one pass. Each press weighs 650,000 The two in. Ajax upsetters, Fig. are also unique that they are the largest their kind built Ajax Mfg. Co. Carried over from the old bolt- making days, forging ma- chine ratings inches (maximum has this Yori date mot whe ° ° ° per cas ids bar diameter upset) give little clew their tonnage. This in. machine has crankshaft in: diameter the journals and in. the ec- centric pin. According Brootzkoos* this would correspond capacity 1950 tons. Stroke the header capacities mechanical power presses the basis their main crankshafts and pins, Table IV, “The Se- the Dryden Press Inc., New punch slide in. and the dis- tance the moving die retracts sideways in. Dies in. high in. deep in. thick can accommo- dated the die seat, allowing ample space for deep impressions like the cylinder head. The machine driven 150 hp. squirrel cage motor which V-belted large fly- wheel air clutch; speed strokes per min. Frame one piece steel casting reinforced single tie rod longitudinally and two cross tie For other articles the forg- ing aluminum, the reader referred the following arti- cles which have appeared THE IRON AGE: “Forging Aluminum Alloys,” Sept. 10, 1942, 41; “Design Alumi- num Forgings,” June 17, 1943, 58. clamps for crosswise rigidity re- sist the enormous spreading pressure developed wedge action when the head forging pierced. The entire unit weighs 500,000 Ib. Tailwheel Job One the practice jobs which both supervision and workers An- derson gained experience while await- ing the head contract materialize illustrated Fig. which shows the five stages required forge 14S aluminum alloy airplane wheel housing from in. billet. Some the chief differences between press and steam hammer forgings are exemplified this piece. press forgings, for example, the metal must helped around the cor- ners more than the case impact forgings. Particularly the pre- blocking draft angles should large, flow lines gentle and radii generous. Flat die cogging, properly done, can big help gathering meta! for the preblocking operation. this first step the die sinker guided more considerations metal flow than blueprint dimensions. operations were performed the 2000 ton hydraulic press, using the top faces the preblock dies for the initial flat die work. pictured the inset, Fig. the boss the far end the housing in. high. order fill the die the flattened two 2000 ton HPM hydraulic presses installed the plant where aluminum alloy cylinder heads are being forged for the Pratt Whitney engine. Note the continuous slug heating furnace between the two presses. THE IRON AGE, May LEFT 2—One the four 4000 ton Clearing mechanical presses installed Anderson, Ind. These are probably the largest presses this type ever built. BELOW 3—Final forg- ing operation the cylinder head performed this in. the single cavity dies can seen the lower right. Note the guide (See also Fig. 10.) 50—THE IRON AGE, May 17, end shown second from the left turned edge deg. produce the rough preblocked mass shown next the cogged billet. additional prob- lem here the formation the deep ribs. and flat panel web section, which later blanked out (extreme right). Note the preblocked form the generous radii used flow the metal gradually into what will later form the ribs. attempt made this stage fill out the ribs the full height. Actual time required the press was sec. for cogging (done three squeezes) and sec. for preblocking. The cogging opera- tion took 175 tons pressure and the preblocking the closed die the full 2000 tons capacity the press. Blocking and finishing formed the same die one the Clearing 4000 ton presses. The sec- ond blow helps fill out the die cav- ities. Here the problem prevent metal the panel section from being shot out into the flash, thus shearing the ribs the parting line the forging, and causing defect re- ferred through.” Although flashing unavoidable and was fairly heavy (in this instance the flash weighs the panels were al- lowed absorb some the excess metal, which was blanked out the trim die. Incidentally was this job that proved the utility employing vent holes get metal down into the die cavities and increase die life bleeding the pressure which other- wise might generated from oil ex- plosions. Two particularly large vent holes were used the bottom the boss cavity mentioned above. Altogether 5000 tail wheel struts were run single set dies the hydraulic and mechanical presses. Corresponding steam hammer dies the nearby Muncie plant Chevrolet would break before they had aver- aged 250 pieces. Forging Cylinder Heads Material for the cylinder heads 18S aluminum alloy furnished the Aluminum Co. America and comes into the plant the form slugs 10% in. diameter in. high, weighing about lb. Prior their receipt the slugs are sawed from cast billets which have been peeled scalped lathe and being soaked 950 deg. for hr. This material aluminum forging alloy containing per cent copper, per cent nickel and 0.5 per cent magnesium. Heat treated and has average ultimate aged, strength 63,000 Ib. per sq. in. and yield strength 47,000 lb. Mini- mum values are 55,000 and 40,000 respectively. material that has been used for aircraft engine pis- tons and was selected for the head strength high temperatures. Although suitable from the de- signers’ point view, 18S some- the forging airplane alumi- num tailwheel strut. The problem here fill out the deep ribs and bosses. From left right. slug, preblocked forging, blocked, finished and trimmed forg- ing. what more hot short than some the other aluminum forging alloys and the cast structure therefore more susceptible cracking under impact blows. This was one the principal reasons why pistons have been forged upsetters and why press equipment and upsetters were chosen place forging hammers for the forged aircraft engine cylin- der head program. Fig. shows the creation the head from slug finished forging ready for heat treatment and machin- ing. After heating the slugs 840- 880 deg. one the S-C continu- ous conveyor furnaces, the forging completed the following stages: (1) Flatten and preblock hy- draulic press (2) Reheat (3) Block mechanical press (4) Finish forge press (5) Trim flash (6) Reheat mechanical (7) Pierce dome and upset base flange upsetter (8) Trim flash (9) Heat treat (10) Pickle and clean. Flattening done the flat faces the octagonal preblocking die and serves flatten the 10% in. diameter cylinder about in. (See Fig. 5). The slug then placed the die cavity with its longest dimension vertical shown Fig. The pre- block die produces the “blob ecto- plasm” (seen Fig. which begins take the first, faint shape the head. Looking the shape the finished head Fig. 5F, apparent that the most difficult part the job filling the so-called rocker box ears which are eccentrically disposed with respect the parting line the die. the finishing die, the ears extend approximately in. below the part- THE IRON AGE, May 1945—5t the eep ion, rm the ade red ent ing line the lower half and 1-15/16 in. above the upper half. These ears begin take their rough form the preblocking die, though obvi- ously not full depth. fact the die cavity the preblocker only in. deep, although the finished diameter the head body 10-1/32 10-1/16 in., approximately equal the original slug diameter. The chief object the preblocker force the metal out the sides and gather metal for the ears. Draft angles the preblocker are not less than deg. and all radii are generous—not less than in. will seen later, presses was trained his job hot slug handed him tongs the heater, and place the Depth cogging de- termined eye, using the ram and mark the housing gage point. Reversal the ram effected when the dies are fully closed and the pumps give indication overload. Preblocking takes the full press ca- pacity 2450 tons, corresponding the relief valve setting 2950 Ib. per sq. in. Flash trimmed Bliss No. 8-60 mechanical press, Fig. then than the range forging temper- atures they leave the heating fur- nace. the blocker dies the rocker box The ears begin shape more. draft angles are still kept generous deg.) and internal and external radii not less than in. Venting the dies resorted order fill out deep corners, particularly the deep rocker box ears the lower half the die. the finishing die, de- tails final shape approach comple- tion and can seen Fig. the sockets for the ports are sunk. the aluminum cylinder head: (A) Slug, (B) flattened slug, (C) pre- blocked forging, (D) blocked, (E) and pierced and upset forging. these factors which account for the long die life obtained. gutter flash used these dies. Die lubricant Graphite Co.’s No. 71G graphite compound mixed with light oil. applied with swab spray nozzle. and preblock takes about 18-20 sec., using one relatively un- skilled operator; about 85-90 pieces are put through hour and 750 800 hr. shift. fact, one the men now running the HPM IRON AGE, May 1945 the rough forgings are loaded the Surface Combustion conveyor fur- nace, Fig. feeding the battery Clearing 4000 ton presses. the operations were first set up, the forg- ing was reheated between the blocking and finishing pressings, but the layout the four big Clearing presses was such that with the aid short monorail conveyors, the forg- ing could carried through both sets dies one heat. Loss tem- perature only about deg., less These are 1.80 in. deep with deg. draft angle. the finisher hollow tong hold for the upsetter operation (Fig. 10), which follows, formed extruding material around man- drel porter bar. The bar has integral collar which engages recess the dies and absorbs the end thrust. these operations Kearns No. 1316 hot die compound used lubricant mixed with the 71G liquid graphite, id pera ing pn, ted obl r temper- fur- ker box The enerous nting fill the ver half die, de- comple- Fig. deg. hollow formed man- has recess the end irns No. sed the rear head, the blocking omitted and instead two ows are struck the finishing die the Clearing press. the case the dies the press, octagonal dies meas- ing in. across and in. thick used. Proper matching ex- emely important this work and precautions are taken attain it. the first place, the presses have designed give rigid guiding slide four corners. addi- two in. diameter guide pins, ig. are employed line the holders and the dies themselves in. diameter lock ring. original setup, deg. taper were used for the vertical ad- stment the lower die since justment the pitman con- ntional stamping presses. When press was first turned over, how- er, this wedge was literally shot like slippery watermelon seed tween thumb and forefinger. had purposely well lubricated pre- sticking, but was found that put dry, oil seepage lubri- ted the wedge and permitted squeezed out. The solution the oblem lay the use flat shim eets, in. and under thickness, ich are placed between the die nks and the die holders. Production the Clearing presses forgings per hr. Most time spent getting the forg- and out the press. takes team seven men handle the plete cycle through the forging trimming presses. Starting with two furnace tenders heaters, charge, the other unload, figure includes the operator ton forging press and handler who lifts the blocked forg- out the backside the die fork engaging the flash and trans- ishing die the second press, ap- from the rear. The erator the second press inserts porter bar (which needed upsetter) and initiates the press push button. Another han- picks off the finished forging the back the second press and nsfers the trim press, which third operator. This oper- removes the forging from the die means the tong hold places tote box. dis- the flash another box. None these men are skilled the sense hammerman and none has spelled off hr. “tricks,” relief periods. Fig. 6—Preblocking the cogged slug the 2000 ton hydraulic press. Fig. 7—Trimming flash from forging mechanical press. THE IRON AGE, May 17, 1945—53 Upsetter Operations For the final forging operation the in. Ajax upsetter, Fig. 10, the heads are again loaded the slat conveyor Surface Combustion furnace and brought temper- ature 840-860 deg. for piercing the dome and upsetting the flange the base the head. single die cavity used (See Fig. right) and the work completed one stroke the machine. Unusual for header dies, two heavy guide pins are em- ployed assure proper matching the die halves. Because the time required close the dies before the piercing tools enter the work and the extra effort position the forging the vertical dies, this necessarily the slowest press operation and out- The head pierced in. diameter punch depth about in. the same time upsetting the flange the base and forcing the metal into all corners the die cav- ity which this time conforms the part blueprint details, including in. corner radii and deg. draft angles. knockout used release the forging from the station- ary die. The punch mounted adaptor the slide and provided with depth adjustment in. govern the ultimate body diameter the head, which held within 1/32 in. This adjustment also controls the 54—THE IRON AGE, 17, 1945 LEFT Charging continuous con- veyor furnace with preblocked forgings. These Surface Com- bustion units feed presses with heated 9—Lifting forged head out the rear the finishing die the second Clear- ing eccentric press means fork engaging the flash. Note the two guide pins which line the sow blocks, also the lock ring the die itself, size and filling the forging, which weighs lb. when should pointed out that even massive machine this type, under the wedging loads imposed the punch, the dies open certain extent result spring the frame, massive is. can takes place the upsetter and the cavities are well vented get the metal down into the corners. Hot die lubricant sprayed from com- pressed air tank hand nozzle. Including the furnace charger, this last operation takes four men. There is, addition the heater, the forg- ing machine operator (who the skilled classification this forge shop) and the off bearer. Forg- ings are transferred drag link small amount flash developed this operation. Final shaping the rocker boxes nes: die: rep tho for die ner bee aft 10¢ irging con- with gings. Com- feed nical eated Clear- pins the die com- this There forg- the this Forg- link (See Fig. the trim press. now the material has been sub- ject much strain and uneven cool- ing but still more less‘in the condition. bring into the “T” condition meet the required mechanical properties, the forgings are heated continuous S-C furnaces 950 deg. for hr., quenched boiling water and artificially aged Ross System ovens 475 deg. for hr., which represents overaging for 18S-T. The forgings are then cleaned caustic soda and given nitric acid bright dip. After partial machining and finning, the forgings are stress relieved 550 deg. for hr. before final machining and shipment the Chevrolet assembly plant Tona- wanda, Die Life There has been some general dis- cussion among forgemen the relative life drop hammer dies and press dies. For the tailwheel land- ing strut, experience showed that 50,000 pieces could run through the same set press dies without re- finishing, whereas drop hammer dies had replaced after making 250 forgings, possibly because this repre- sented 1200 2500 impact blows. such comparisons are obtainable the cylinder heads since this job was never run through the hammers. Data the press dies are revealing themselves, however. All the dies used the hydraulic presses, the mechanical presses and the upsetters Anderson are cut from Heppenstal Hardtem chrome- nickel-molybdenum com- monly used for drop hammer dies. the treated state, the steel tem- pered 1150-1200 deg. hard- ness 48-52 Scleroscope (36-39 Re). the preblocker dies the HPM presses, 60,000 70,000 heads have been obtained without resinking the dies, while 20,000 25,000 heads have been obtained off the blocking and finishing dies, and about the same number off the Ajax upsetter dies. This not say that die repairs have been though the dies have not opened “washed” produce oversized forgings, the blocking and finishing dies have developed cracks the cor- ners after producing 10,000 12,000 head forgings. Such cracks have been routed out Hydro-Tel and welded with the atomic hydrogen arc after the die block was preheated 1000 deg. Filler material the same analysis the base metal but somewhat softer deposited and hence readily machinable welded. One the integral plugs the Clearing press finishing dies which the port cavities broke off due the eccentric loading the metal over this tapered dome. was read- ily repaired boring out the die and inserting tool steel plug the same size. Particularly the start was trouble experienced with dies crack- ing, work sticking and laps and seams developing thin sections the work. These difficulties were solved increasing the draft angles wher- ever possible, making corner radii large possible and general gen- erating easier flow lines the initial stages forming. Over 50,000 heads have been pierced with punches made Finkl Durodi steel heat treated 43-48 Re. Origi- nally, was planned water cool these punches but experience proved this unnecessary. The only failures here have been the adaptor which holds the punch the slide. latter held the cross pin, the hole for which weakens the adaptor and eventually leads fatigue failure due repeated flexure. Conclusions far Chevrolet officials are concerned, press forging these heads and other trial parts has been highly satisfactory and undoubtedly this experience will affect postwar manufacturing methods. Scrap has been held down less than 0.1 per cent. Due the fact that the work completed one, the most, two strikes, they feel they can get double the production per shift from presses from hammers and less cost. Hammermen command the high- est wage rates the metal working industry, whereas relatively un- skilled man can operate power press with little training. All the skill built into the dies and the machines. Similarly because the work less laborious, only single crew required operate press instead several crews having spell each other off. 1G. tong hold porter bar the finishing dies the 4000 ton mechanical press enables the work gripped for loading into the in. upsetter shown which completes the forging. (See also Figs. and 5F.) THE IRON AGE, May ° Determination Moisture Electrode determination moisture the coating welding electrodes quite difficult problem the usual methods for de- termining moisture are too lengthy when applied electrode coatings and cannot used for works control. One method recently de- scribes the routine tests carried out before the results are available this method cannot considered very satisfactory. IG. semi-automatic moisture tester. (Left) Rapid balance and drying dishes, with time clock background. Automatic RIGHT \ Electric the Brabender semi-automatic moisture tester. 56—THE IRON AGE, May 1945 HAIM Arc Mfg. Co., Ltd. England ° The moisture problem has always been carefully studied electrode manufacturers, and seems worth while give account method which was adopted short while ago the Are Mfg. Co., Ltd., for the production control its electrode view the illumi- nated dial (B, Fig. the Brabender moisture tester. ° ° ° plant. The main advantage this new moisture test that results are available 15-35 min. after taking the samples, and tests can carried out unskilled persons. The moisture determinations are carried out Brabender semi-auto- matic moisture tester which well known other industries, for ex- ample; flour mills, bakeries, brew- eries, tobacco factories, etc., where also necessary keep constant the moisture content the handled goods. The determination moisture coal means the Brabender moisture tester has been described Rees and Bursack,’ and Anderson; Control Moisture Electrode Coatings. THe Vol. 153 (1944), No. 22, pp. 48-51. Equipment for Determining Moisture Coal. Ind. Eng. Chemistry. An. Ed. Vol. (1942), No. pp. 729-731. numerous other papers have been published the Brabender appa- ratus and its use, but far known the author, this device has mit iar she ing Fig * ove cal Coatings this are the out are well brew- nstant the ion the been and oisture ture in. Ed. been appa- device has never been applied the deter- coatings. Apparatus Described The apparatus and all the auxil- iaries necessary for the test are shown Fig. better understand- ing the principle can achieved studying the schematic drawing, Fig. The test carried out drying oven which contains automatic bal- ance constructed that the sample weighed without being re- maved from the oven. The apparatus takes samples the same time. The sample dishes carry exactly gm. crushed coating weighed out the rapid balance. These are put into the oven through door (at the left) and are placed the rotating table turning the handwheel the top the apparatus. When all the samples are introduced this door closed. electric heater (below) Loss Drying time, min. 1G. 4—Loss moisture versus drying time deg. Drying time, min. 6—Loss moisture versus drying time 155 deg. new method for moisture determination arc welding electrode coatings described which claimed superior other methods regards speed and simplicity. The article was inspired the description the technique employed the Cali- fornia Shipbuilding Corp., which appeared The Iron Age year ago. reprinted from the British journal thermostatically controlled ther- mometer keeps the temperature inside the drying chamber any desired level 180 deg. within deg. (The specific drying time for particular type coating found experiment.) The samples are brought succession over the automatic turning the handwheel. press- ing lever the three fingers the balance are raised and weigh the sam- ple the dish. The balance indicates the loss weight due evapora- tion moisture, and the initial weight (10 gm.) always the same this loss can indicated percen- tage moisture the illuminated dial the balance. close this dial shown Fig. Readings can made with accuracy 0.1 per Loss moisture, per cent percent Loss cent. After moving lever back into its original position another dish brought over the balance turn- ing the handwheel. The lever pressed again and the weighing pro- cedure repeated. The advantage this method ob- vious. time lost cooling be- fore weighing, tests can repeated until constant weight reached and the moisture content can immediately quired. Graphs Explained Before introducing the apparatus into routine laboratory neces- sary establish correct drying times and temperatures. Four drying graphs are given Figs. and fer 115, 135, 155 and 175 deg. C., respec- Drying time, min. 5—Loss moisture versus drying time 135 deg. Drying time, min. 7—Loss moisture versus drying time 175 deg. THE IRON AGE, May 1945—57 8 = 4 tively. The loss weight drying (or moisture content) plotted against drying time for three differ- ent types electrode coatings: FLW represents coating contain- ing relatively large amount cellulosic material. FAC represents general type coating (50 per cent rutile). BGL iron oxide coating (dead soft deposit). From these graphs can seen that 115 and 135 deg. constant weight cannot achieved even when the drying time extended min. However, increasing the drying temperature 175 deg. coatings FAC and BGL may completely dried within min. The FLW type requires min. drying 175 deg. This temperature was considered the practicable limit higher tempera- tures might cause the cellulose break that false results for moisture would obtained. The fact should not overlooked that determinations are made batches ten the average time re- quired obtain one result consid- erably less than the heating time found experiment. will seen from the graphs that the greater part the moisture driven off the first min., the re- mainder being very small fraction the total; therefore permis- sible some cases shorten the drying time and take readings after min. great accuracy not re- quired. NEW type burring tool, invented Vultee Aircraft Corp., San Diego, currently saving considerable time and money the process removing burrs from the edges sheet metal airplane parts, formerly means files conventional power driven rotary cutters. The latter were reasonably fast and efficient when was necessary .burr parts with straight edges; but, when the edges the parts were irregularly shaped, manual filing was frequently required. The Hamm invention provides power driven tool which can used for all sheet metal edge burring, in- cluding rough corners. The tool has cylindrical metal body with two rotary cutters its face and adjustable metal base which can readily attached electric drill motor. spindle the 58—THE IRON AGE, May 1945 was found that the most practi- cal way sampling was bend the electrode over former, Fig. and break the chips coating into smaller pieces about in. length. Weighing must carried out rap- idly once the coating broken up, any delay will result low mois- ture figures. The special balance shown Fig. permits rapid weigh- ing 0.05 gm. accuracy. The oil damping device the balance gives almost dead-beat reading. The dishes are numbered allow identi- fication the sample. Another interesting application this apparatus, apart from its use Power Tool Burrs Edges base and suitable gears the body make possible for the drill motor drive the cutters, and the cutters can spaced that sheet any thickness can passed between them. Because the cutters are tapered, Fig. 8—Bending device for removing coatings from electrodes. routine instrument, for the estab- lishment the proper drying condi- tions when new type electrode first goes into production, especially cases where necessary re- _tain definite amount moisture the coating, as, for instance, shielded arc electrodes. such case few electrodes are extruded first, the coating stripped off and the initial moisture deter- mined. Drying tests are then carried out under carefully controlled condi- tions, drying interrupted and the re- maining moisture measured. The time required for correct drying can thus easily ascertained. Sheet V-shaped groove provided for the work and since only small portion the work touched the cutters any one time, the contours the part will not appreciably affect the functioning the tool. redir type and 1928 struc con shell shell obse labo con ° ° ° HIS view the tool shows (at the left) the rotary cut- ters which greatly facilitate the proc- ess burring the edges sheet metal parts. The tapered cutters may ad- justed that sheet any thickness can passed between them. : cas 0.3 0.0 al flu er the ‘tion the the “Etching Technique,” (THE IRON AGE, Aug. 28, 1941), Corson redirected attention unusual type etched structure first observed and described him the Trans- actions the American Institute Mining and Metallurgical Engineers 1928 (Vol. 80, pp. 249-300). This structure, which occurred particularly the iron-silicon alloys high sili- con content, christened “barley shell” structure from resemblance the markings wide open barley shells. This type structure was observed frequently the laboratory when etching specimens high silicon acid resisting irons, and possible record some the conditions etching under which obtained and make some obser- vations its characteristics. Dealing with commercial iron-sili- con alloys the type used the manufacture corrosion resisting silicon, 0.10 0.60 per cent carbon, 0.30 0.70 per cent manganese and 0.05 0.20 per cent phosphorus, the barley shell structure was produced most readily simple immersion reagent containing both and acids. reagent consist- ing one part per cent picric acid and two parts hydro- fluoric acid, room temperature, pro- duced structure this type sec. immersion time. Deep etch- ing with this reagent caused thick- ening the barley shell markings and variations strength the reagent and etching time modified only slightly the appearance the structure. The needles were found equal- distributed both the silico-ferrite and the graphite areas. Under con- ditions light etching the needles did not cross interdendritic holes the specimen, but deeper etching caused spread the structure which eventually obscured small Corson’s observation that ticularly dense barley shell structure was produced specimen which had been water-quenched from 1832 series articles entitled The “barley shell" structure first observed Corson the micro-examination iron-silicon alloys the subject further study from which the author concludes that these strange markings are not the true structure the alloys specimens. These struc- tures, has been found, can also produced silicon-free speci- mens with etching reagents having some silicon content. deg. been confirmed, nor does age carbon the alloy appear affect the forma- tion this structure—an observation which again contrary that re- ported Corson. Commercial alloys the above com- position consist essentially single metallic phase (silico-ferrite) gether with graphite. With silicon content excess 15.5 per cent, second metallic phase appears and such two phase alloys when etched above described develop barley shell structure. The true normal structure the alloys developed Lichfield-Staffs; England immersion etching using contain- ing one part nitric acid, one part hy- acid and six parts water for period sec. room temperature. Under light etching conditions the barley-shell structure appears trans- parent, and under the microscope possible altering the focus observe either the barley-shell needles either the normal structures the same field, depending the silicon content the specimen. Structure Not Easily Erased Treatment the specimens etched TABLE Results Etching Experiments Electrolytic Armco and Per Cent Silicon Iron, Using the Picric Acid Reagent for ment Material No. Vessel Fresh solution Fresh solution Platinum Platinum Platinum Etching Solution Used after standing hr. Barley shell Used after standing hr. vessel experiment plus 50% fresh Used after standing hr. vessel Used after standing hr. with STRUCTURE 15% Silicon- tron Armco and Electrolytic Barley shell Barley shell Barley shell etching Barley shell Barley shell Normal Barley shell powdered silica bottom Platinum Platinum Barley shell Barley shell Used after hr. with powdered giass bottom Barley shell Barley shell Silicon iron dissolved solution, and 50% fresh solution added. Barley shell “normal” structure for high-silicon one which shows silico- ferrite matrix and graphite only, with trace the barley shell structure. THE IRON AGE, May 17, 1945—59 trode cially re- are ipped eter- rried ondi- thus | | Glass Glass Lead Lead Lead Fresh solution..................| Normal iron etched for sec. Corson's re- agent which had been stored platinum dish for hr., showing bar- ley shell structure. 120 diameters. 1G. 2—Silicon iron etched for sec. which had been diameters. 3—Silicon iron etched for sec. Corson's reagent stored platinum dish for hr. 600 diameters. IRON AGE, May 17, 1945 show the barley shell structure with boiling water and organic sol- vents did not remove the structure; light rubbing dry cloth did not entirely efface it, and after deep etch the structure survived quite vio- lent rubbing dry cloth. These observations are sufficient show that the structure cannot regarded merely layer crystals deposited from the etching solution. After lightly polishing diaman- ley tine pad specimen showing dense barley-shell structure, the tops the thes individual needles appeared have been ground away, leaving flat “pla- teaus” micro-dimensiors. Further polishing removed the needle struc- ture completely, leaving flat polished surface. The barley shell structure acid could erased completely care- cere ful second etch with the nitric-hydro- fluoric acid reagent and the normal structure silico-ferrite and graphite revealed. was found that the barley shell structure could produced sev- eral etching reagents containing hy- drofluoric acid either immersion hydrofluoric acid itself, under condi- tions immersion, “normal” etching was recorded and structure was produced only in- the intensity the attack this reagent electrolytic etch- reagent the concentration common- used for the etching high-silicon irons behaved similar manner, and with this reagent the barley shell structure could obtained either electrolytic etching increasing the acid concentration the reagent. The barley shell structure produced the concentrated oric acid reagent was obliterated and the normal structure developed the dilution this reagent with water; similarly, the barley-shell structure obtained the picric hydrofluoric acid reagent was removed and the normal structure revealed fol- lowing etch with nitric-hydrofluoric acid reagent the normal concentra- tion. Although the barley shell structure was produced readily silicon-iron alloy, many experiments with the etching reagents described failed produce this structure variety other ferrous materials, including specimen pure (electrolytic) iron supplied Dr. Wrazej. recent paper* the latter the appearance barley shell mark- ings recorded pure (electrolytic) iron, plain carbon steel and cast iron addition iron-silicon alloys. view this, previous experiments or were repeated and number fur- ther investigations were made using *The Apparent Microstructure, Pro- duced Hydrofluoric Acid Etching Re- agents Pure Iron and Iron-Silicon Al- loys,” Journal the Iron and Steel In- stitute, 1944, No. pp. 227 236 specimens electrolytic and Armco iron. These experiments, described below, have resulted the discovery the conditions under which the bar- ley shell structure occurs materials other than silicon iron when using these etching reagents. When using Corson’s the picric The etching solutions were made follows, using A.R. chemicals through- out: Corson’s Reagent: parts hydrofluoric acid, part nitric acid and parts gly- cerol. Picric Acid Reagent: part hydro- fluoric acid and part saturated solution picric acid alcohol. acid reagent** under the conditions specified Wrazej, provided the reagents were freshly prepared, not single instance the barley shell structure electrolytic Armco iron was produced after etch glass vessel. Both these reagents freshly prepared and used under the same conditions speci- mens acid-resisting silicon iron containing per cent silicon invariably produced the barley shell structure. the course the experiments, the observation was made that these reagents were allowed stand glass vessel several hours prior use, then when used for the etch- ing electrolytic Armco iron they produced barley shell structure hav- ing the same appearance that found silicon iron when etched with the freshly prepared solutions. The observation that the etching effect these reagents when applied elec- Armco iron was influenced their contact with glass vessels suggested number further experi- ments, the results which are record- the accompanying table. Influence Glass Vessels was found that using the reagents dishes plati