The Iron Age 1945-09-06: Vol 156 Iss 10

VAN DEVENTER President and Editoric! Directer BAUR Vice-President General Manager LEONARD Assistant General Manager HAYES Advertising Manager JOHNSON, Manager Reader Service and Market Research BAUR, Production Manager Promotion Manager Executive Offices and Séth 39, Pa., U.S.A. and Advertising 100 East 42nd New York 17, Business Managers New York New East 42nd St. 100 East Cleveland Guardian Bidg. Park Chilton Angeles 2420 Cheremoya Ave. ° Owned Published CHILTON COMPANY OFFICERS AND DIRECTORS MUSSELMAN, JOS. FAHRENDORF CHASE WILLIAM BARBER, Treasurer JOHN BLAIR THOMAS KANE CHARLES Member, Business Papert Foreign, $15 yeor. 1945, by Chitten Company AGE Vol. 156, No. Editorial Butter From Coal and Steel From Milk Technical Articles Metals, Finishes, and Finishing Processes Trepanning Welded Joints for Defects Graphite Molds for Short-Run Castings Turbosupercharger Production Details September 1945 Selection and Use Diamond Tools (Part II) New Equipment Features News Front Assembly Line Washington West Coast Personals and Obituaries Dear Editor This Industrial News Industry News and Markets Nickel Industry Girds for Peace Aluminum Markets Expand Goodrich Construction Contract Let Sees Pct. More Jobs South Industry Technicians Remain Pacific Army Lists 262 Surplus Plants Maritime Ships Biggest Steel User Batcheller Promises Maximum Sales Chicago Jobs Jump Machine Tool Market Developments Nonferrous Metals News and Iron and Steel Scrap News and Prices Comparison Prices by. Week and Year Finished and Semi-Finished Steel Prices Warehouse and Steel Prices Iron and Steel Pipe Tubing Prices Exceptions Steel Price Schedule Pig Iron and Coke Bolts and Nut Stainless Steel and Ferroalloy Prices ° ° Index Advertisers 296 } 4 110 114 a a 126 129 138 4 140 | 142 168 190 191 a > Like Money Deposit Yes, steel Ryerson warehouses like money deposit—there for you draw on, the amounts you need. More than 10,000 kinds, shapes and sizes are typical stocks our eleven steel-service plants. Steel from our stocks has valiantly served the war effort, will now serve the peace. met tough situations, almost without number, where steel—a piece, few pounds, many tons—was needed immedi- ately avert production delays. met tough situations the technical side, too—situations where our engineers and metallurgists have been able find way when way had found. cutting and otherwise prepar- ing steel meet ticklish specifications, also done exceptional things. Furnishing steel promptly—the kinds and quantities wanted—has been our business for 103 years. Stocks these days have not always been balance from size stand- point, because the tremendous war de- mand for steel. But our stocks are the nation’s largest. And they are here for you draw on. For Stock List and Data Book, write our plant that nearest you. JOSEPH RYERSON SON, INC. Steel-Service Plants Chicago, Detroit, St. Cincinnati, Cleveland, Pittsburgh Buffalo, New York, Boston RYERSON STEEL 66—THE AGE, September 1945 4 | | = ° a YAN and BAUR Generel Stef Editor Editers JACK HIGHT WINTERS ALBIN JOHN ANTHONY Assistants SCHIEN Pittsburgh Pork Chicago Otis MOFFETT HARDY National Press LLOYD Guardian Bidg, Woodword WORTH HALE Sen Market ROBERT Cincinnati FRAZAR Boston HUGH SHARP Milwoukee SANDERSON Ont. RAYMOND Les Angeles Birminghom ROY EDMONDS JAMES DOUGLAS Butter From Coal and Steel From Milk SEE the papers,” the estimable Mr. Dooley used say, that the Germans had discovered how make butter from coal. Some people will probably jump the conclusions that the days the cow and the milkmaid are numbered and that the chief function the bovines hereafter will hang beef hooks butcher shops, least until science finds way produce synthetic steaks from sawdust other plentiful material. Personally, don’t think there much danger that. haven’t tasted underground butter yet, but even were good mar- garine, won’t put the milch cow out business. Things just not work out that way, fortunately for most us. And cows are more obedient the demands the public than are coal miners. should hate see John Lewis control the contents our baby bottles. After all, one good thing usually helps another, especially the field materials. During the past fifty years, thousands upon thousands new materials have been discovered and produced. Some them were going put the steel companies out business, but far they haven’t. And defy you name any one widely used material fifty years ago that not produced and used today even greater propor- tion per capita, which the only way measure it. Over year ago eminent chemist speaking before the American Chemica! Society revealed the astonishing fact that since Pearl Harbor more than 2000 new materials, materials hitherto unusable because their rarity, had been discovered developed the availability stage. Think that! And every one them contains iron and steel. Butter from coal. Would you surprised told you that every quart milk has steel it? And aluminum, brass, sand and paint also. Steel milk? How about the steel wire the dairy farm fences the sheet steel the milk cans the railroad tracks and equipment that transport it? the factories making milk products? How about sand the glass milk bottles and paint the milk wagons? Yes, indeed, there some steel and iron every other good ma- terial. indirect content, course, but most sizable one. That why are content remain, always have been, Ace. long alphabets remain the most important letters them, from the industrial standpoint, will Fe. Our industry should welcome the 2000 newcomers who have joined the procession materials. For each one them, its production, distribution and use, will call its elder brother for support. MILLER 4 \ ‘ | Metal-wise Men Ready Help You Visit any Inland’s properties and you will meet men who live and work with ments. All are steelmakers highest qualifications, and many them rank high among America’s foremost authori- ties the production and use steel. Quite frequently you will meet metal- wise men Inland helping manufac- turer solve problems steel selection, part design, and manufacturing method. Inland specialist, wise the ways making and fabricating steel, always ready help you. steel—they are the metal-wise men Inland. They will found mines and quarries, using their special training and skill assembling selected raw materials —ore, coal, and limestone. Only metal-wise men operate the. Inland blast furnaces, open hearth fur- naces, and rolling mills—and staff the metallurgical and inspection depart- INLAND STEEL COMPANY Dearborn St., Chicago Illinois St. Levis St. Paul q eke 4 ! 3 pan Sept. 1945 French government plans call for the replacement 265,000 the oldest the machine tool industry. About 125,000 these are expected imported Great Britain, Sweden, and DeGaulle's government envisions new combine the French industry which government would have the largest share the capital, charged with the tools heretofore imported. Automobile dealers are afraid that the new price arrangements new passenger cars will mean that they may get the squeeze, retailers other lines feel tha they are. Establishment the price ceilings will cause precipitous drop used car prices, warranted used car prices have been many cases far above original 1942 ceilings. Fisher asking steel delivery for 15,000 car bodies day 1946, the bag day production year. Steel requirements for Fisher alone would the neighborhood 1,687,500 tons. The British iron and steel industry has not yet started competition and African markets. Sweden, now direct shipping contact with Africa and the Iberian peninsula, dominating the market for alloy, tool steels and electrical machinery. 122 blast furnaces left undamaged the war France and Lorraine, only were blast July, with daily average capacity 270 tons. Despite cancellations there are still thousands jobs filled the coast. The jobs are longer war jobs incomes swelled long overtime hours. West Coast business men are for appointment assistant director OWMR for the West Coast. Trepanning has proved valuable welding inspection tool for revealing fitup, plate condition, and preparation and procedure the weld and relatively low cost. However, unlike rays, radium Magnaflux, trepanning destructive type and covers only small areas. Improved surface finish being obtained aircraft thermal expansion light-alloy skin prior reveting. Electrically heated blankets are placed contact with the skin plating. The electric current passing through the blanket raises the temperature and expands the skin plating. this heated condition the panels are drilled and riveted along the edges. After the removal the blankrt, skin cools and becomes taut. Riveting then completed the normal manner and resulting component free from quilting and effects. present, only wings are treated, but experience gained indicates that method may applied with advantage all external plating, particularly thin gages. view the better controls being introduced and more complicated shapes cast centrifugally, the use graphite electrode rod molds offers many advantages Less storage space needed; graphite more easily machined with normal carbon steel and its rapid heat transfer aids progressive solidification. Graphite inserts may eliminate such machining operations hole boring, and within the realm possibility that undercuts and irregular contours will cast rather than machined. high ferritic 8.5 pct nickel steel with good mechanical ties very low temperatures, said low 200 deg. Now experimenta production Lukens, this steel may offer prospect use the low temperatures involved petroleum dewaxing and liquid air equipment. WPB survey 5001 companies representing key industries equal pct 1939-1941 average this month, 112 pct December, and 187 June 1946. an i | | | | | — 4 Metals, Finishes, And Finishing EDWARD ENGEL Engineer, Technical Processes Division, Colonial Alloys Co., IRON AGE, September 1945 ITH the metals industry swing from war production back the innumerable varieties civilian products, the selection the proper metal, finish, and finishing process again becomes matter paramount competitive importance. Hence this complete, unique, and functional correlation tremen- dous mass hitherto widely scat- tered data can most timely use- fulness. The tabularized data which appear this issue and the three following issues THE IRON AGE present general view the metal surface processes, and they serve supplement the “Metal Comparison Charts” which appeared THE IRON AGE, issue March 30, 1944. Herein, the following data charts are pre- sented: reference .cleanliness there are three conditions metal sur- faces: (1) Mechanical. (2) Physical. (3) Chemical cleanliness. mechanically clean surface sig- nifies the absence oils, greases, solid particle dirt and products oxidation, but not necessarily the products all chemical reactions. chemically clean surface means the presence chemical reaction products, foreign matter such oil, grease, dirt finger prints. metal surface must wet, i.e., retain water considered chemically clean. Ordi- narily, cleaning means alkaline solution treatment presents chemi- cally clean surface; however, there are instances where wettable sur- face obtained following poorly compounded alkaline cleaning treat- ment and spite apparently chemically clean surface, trouble oc- curs the adhesion the plated de- posit. Under such circumstances the basis metal may rechecked for chemical cleanliness immersion suitable dilute acid after the alkaline cleaner. the surface the metal does not wet following the acid dip, signifies that the alkaline solution treatment has left deposited pores the metal. Cleaning Procedures Operations for the removal met- allic substances are: (1) Barrel tumbling. (2) Sand shot blasting. (3) Wheel belt grinding. (4) Seratch brushing, and with more limited results. (5) Acid pickling. Cleaning Procedures Mineral oils and greases them- selves mixture with other oils substances are best removed treatment petroleum referred mineral solvents. Min- eral solvents may the nature kerosene gasoline napthas (Red Label solvents). However, due the fire hazards and high insurance in- volved the use Red Label sol- vents, “safety solvents” are preferred, solvents with flash point over 100° For small parts, chlorinated hydrocarbon solvents, generally used vapor form are very efficient de- greasers and they are considered having flash point. The removal oils and greases mineral solvents may also cause loosely held solid particle dirt removed, thus making the surface suitable for most paint applications, particularly finger print neutral- izer incorporated with the mineral solvent. But, under circumstance cleaning degreasing leaves chemically clean surface and plat- ing will adhere metal surface unless chemically clean. con- nection with degreasing, the factors efficiency solvent are: (1) The solvency power, i.e., the amount oils the solvent removes before becomes too saturated for further efficient use. (2) The speed solvency, i.e., the length time required remove the oils. (3) The penetrating power—refers ability the solvent remove oils from deep (4) The neutralization finger prints. Finger print neutralization very important “painting” rust preventive film follow degreas- ing. (5) some instances impor- tant that there ability protect the surface for varying periods time, from “rusting” and/or from fungus attack. comparatively new approach for degreasing and cleaning metals the use emulsifiable solvent clean- ers which are very effective and eco- nomical the removal heavy TABLE TEST IDENTIFICATION METAL SURFACES Place drop the specified solution the metal for 0.5 min. Sequence “A” for testing white metals when not certain whether surface treated not. Sequence “B” for testing white plated surfaces, and sequence for yellow and colored metal surfaces. (1) Hot pct NaOH Violent Slight Reaction Reaction May Proceed (2) SEQUENCE “A” (2) Concentrated and transfer the reac- tion product filter paper and add drop H2S04, 1.3 Potas- sium Ferricyanide Per Gal Water (3) Concentrated and Red Reaction. Transfer the Reaction Product Filter Paper and add Excess Ammonia (4) pct Yellow Slight Reaction Reaction Nitric Acid Colorless Reaction Reaction (1) Concentrated Green Reaction. Trans- fer Reaction Product Filter Paper and Add Ammonia and. Dimeth- glyoxime Red-Pink Spot Spot Carbonized Softened Content Test for Nickel Blue Spot and and Chromium STAINLESS STEEL (2) Concentrated HCi, Colorless Reaction. Transfer Reaction Prod- uct Filter Paper and Treat the Reverse Side the Paper With Powdered Cacotheline Violet Spot SEQUENCE (3) Color From Test (2), Then Place Drop Concentrated HNO3 and Transfer Reaction Filter Paper and Add Ammonia and Sodium-Sulfide White Yellow Spot Spot SEQUENCE Biue Reaction Copper Content (Test for Nickel) MONEL WHITE BRASS (4) Brown Re- action Test (3), Then Transfer the Reaction Product Filter Paper and Add NaOH White Brown-Black Spot Spot Apply Open Flame the “Colored” Metal Surface Reaction Uneffected Surface Add Drop Concentrated Biue Reaction Violent (Check for Silver) (5) Concentrated Aqua Regia Will Not Effect RHODIUM But Will Dissolve Though Con- centrated Nitric Acid Will Effect Neither PLATINUM RHODIUM Color Faded- But Reaction Metal 100 prow eas dine sourz ysodep “sjods 72—THE IRON AGE, September 1945 greas gener temp lowe tends prod are mine with true caus the dirt the sor sol ] greases and oil and solid dirt. generally used immersion room temperature forced spray fol- lowed hot water dip spray. "Chemical" Cleaning Procedures treatment alkaline solution tends present chemically clean surface metal, i.e., soil and the products most reactions well vegetable and animal oils are removed. However, mechani- cleaning performed nor are oils dissolved. connection with the removal mineral oils, true that alkaline mixture may cause thin film oil removed the heat the solution through the mechanical impingement the solution the lifting action the dirt being removed; however, most the mineral oil removed from the metal surface not dissolved ab- sorbed the solution. Mineral removed alkaline solution floats the surface the solution film and the metal will recoated with oil when with- drawn from the solution. With the exception aluminum, alkaline solutions not tend re- move oxides scale. Properly compounded alkaline cleaners contain detergents. Deter- gents affect soil changing from water insoluble water soluble, addition which they increase the power solution wet the surface metal, reducing the surface tension the solution. Detergents also increase the penetration, rinsibil- ity and deflocculation values (suspen- sion dirt). Metal Preparation Equipment the use solvents solutions more efficient action obtained the the metal, i.e., solution agitation mechanical means, e.g., air, steam, spray operation, the movement the metal being treated, approaches. the instance acid pickling metals has been indicated that the use forced spray (as does the use acid inhibitor) tends conserve acid, lessens the attack the metal and minimizes hydrogen absorption, thus lowering the subsequent embrit- tlement the metal. both acid pickling and alka- line cleaning the electrolytic proce- dures result better efficiencies than immersion treatments. Typical Preparation Procedures When metal formed, drawn, stamped worked, cooling oils and/ lubricants are almost always used. Electrodeposit the Following pet spray 290 140 Chromium and thickness, 0.000325 0.000125 ASTM (5) Copper and nickel total thickness, (F.S.) A-5168-39T 0.00075 (L.S.) (min) thickness (if 0.00001 0.00001 0.00001 pet salt spray resistance, hr... resistance, 250 150 (8) Tin 0.0003 0.0005 0.0002 0.0002 pet salt soray resistance, 250 trodeposits zinc die castings............... designation B-142-41T Copper (min), 0.0004 0.000 0.0002 Final nickel (min), 0.0005 0.0003 Chromium required, 0.00001 0.0001 0.00001 (11) Chromium thickness zinc, 0.000025 spray tests zinc are not worthy too much emphasis evaluating the corrosion protection under normal atmospheric conditions. Black (Moly nickel 0.00003 spray resistance. These oils must removed between operations order obtain effec- tiveness subsequent operation, order make inspection, for storage purposes. (See table for cutting oil, data and their re- moval.) addition the removal the oil, may necessary apply suitable rust-preventive oil com- pound, the same time the cutting oils are removed, the rust-preven- tive oils and compounds are effective. Rust preventives, well “paints,” also are offered with fungus inhibi- tives, fungus growth one the major causes for rapid corrosion metals and fabrics. has been indicated, prior “painting” metal must mechani- cally and physically clean order present surface which will permit bond for “paint.” Prior plating. metal surface TABLE SALT SPRAY RESISTANCES VARIOUS THICKNESSES ELECTRODEPOSITS (Army and Navy Specification AN-QQ-S-91, Salt Spray Testing Most the data are from the American Society for Testing Materials Tentative Anodized aluminum dependent alloy and time treat- ment has 250 over 1000 hr, pct salt spray resistance. Some_proprie- tary white-alloy deposits have about 200 salt spray resistance. lacquered work resists 100 more pct salt spray and good lac- quer job one which resists over hr. tin generally 0.00003 in. thick and equals 0.5 base box; hot-dip tinning prior the war was Ib. base box, equal thickness 0.00012 in. Terne plate, formerly pet pct tin, now Types Exposure (3% min deposit) salt Excellent must chemically clean well mechanically and physically clean. Much the metal presented the plater has oils present, which often are removed solvent degreasing, which may followed pickling alkaline cleaning both. The metal plated usually polished after physically cleaned, after which more efficient remove the pol- ishing compounds degreasing order not contaminate the buffing, “coloring,” which follows the pol- ishing. After buffing, the metal chemi- cally cleaned prior plating, al- though vapor-phase degreasing may proceed chemical cleaning. The re- moval buffing compounds net al- ways easy operation there are well over 100 different combinations buffing compounds. The metal should cleaned imme- diately after buffing prevent the THE IRON AGE, September i | | ELECTROLYTIC (GALVANIC) CORROSION FACTORS (Negative potentials, volts, measured calomel half-cell using normal sodium chloride, plus 0.3 pet hydrogen peroxide solution and calomel electrode.) Magnesium (Mg) alloys TABLE alloy AM-57S-alloy Aluminum alloy 220-T4 and Allovs 365 Certain proprietary white-alloy deposits have potential between chrome plate and brass. exposed contact under atmospheric conditions, metal will electrolytically protective (anodic) any metal shown the columns its right. metal will protective any metal with lower negative value and the degree protection will increase proportion the differences their potential values. Zinc and cadmium are the only commercial metallic deposits which are anodically protective steel. lesser All other metallic deposits will protective steel alu- degree, zinc cadmium will protective aluminum. minum only physically, the effectiveness the physical protection dependent the degree porosity, the ex- Pure and alloy alloys alloys cadmium A-17 alloy alloys 24ST mild steel tent which moisture excluded from entrance the basis metal. possible formation insoluble metal- lic soaps, which may occur the buffed metal permitted held over. instances where immediate plating cannot arranged, there are available compounds which will per- mit the buffed metal cleaned, then rust inhibited with water- soluble film which will enable the work held over prior plating. Preparation Specific Metals Aluminum and its alloys are de- greased solvent degreasers when excessive oil present, otherwise well-compounded alkaline cleaner will Exposure Site: (1) Non Industrial (2) Industria! (3) Marine 0.000025 0.0005 SCORE 100 (perfect) Pct surface rusted.............. The protective nature zinc and contrast with the lack and the definitely accelerating effect and nickel exert the corrosion base iron; thus, rust will “bleed” from the pores chromium _and nickel plate. 74—THE IRON AGE, September 1945 _ Nickel, Thickness, In. remove dirt very effectively, though care must taken not use tem- peratures concentrations that are too high the metal will badly etched. Aluminum alkaline cleaners tend remove oxides, though there are acid type deoxidizing solutions the mar- ket which are more effective for the removal the oxides, particularly for preparing the metal for spot welding. Following alkaline type cleaner the metal may immersed one the proprietary acid de- TABLE ATMOSPHERIC EXPOSURE TESTS ELECTROPLATED STEEL (Results months exposure tests conducted American Society for Testing Materials, American Society and National Bureau Cadmium, Thickness, Chrome 0.001 Nickel 0.001 0.0002 0.0005 0.001 (Cr Chromium 0.00002 (excellent) (very good) (good) (fair (poor) *chtomium (plate) stainless steel Copper 18-8 Monel silver nickel (plate) Inconel tric acid solution. Brass more effectively cleaned especially following buffing, ca- (electrolytic) cleaning, though there are few well-compounded soak cleaners that meet many require- ments for copper alloys. Forced spray other impingement cleaning procedures are much more effective when using soak cleaners than the use still baths. Vapor-phase de- greasing also effective removing some types buffing compounds. The cleaning presents many diverse conditions and must borne mind that following the Nickel-Chrome-Copper, TABLE COMPARATIVE FRICTIONAL PROPERTIES METAL SURFACES Frictional Factors Coefficient friction (sliding) Static friction Nickel Chromium Chromium Nickel 0.13 0.16 0.17 0.18 Babbitt Babbitt Copper Copper 0.18 0.19 0.20 100 noted that chromium surfaces have approximately one third less friction than other surfaces. cleaning cycle, care should taken prevent subsequent oxidation. rinse hot water follows the alka- line cleaning, weighable rust ap- pears (shown the Gulbransen vacuum balance) within min. after drying. Therefore, the work plated following the cleaning cycle must kept wet. the work “painted” fol- lowing the cleaning cycle, should rinsed cold water keep from drying too quickly protective dip should given the metal either light rust-preventive oil the organic type water-soluble rust- inhibitor referred previously. Zine diecastings present peculiar COMPARISONS PICKLING—DEGREASING—CLEANING PROCEDURES Sand and Safety Emulsifiable and Electro- Shot Solvent Solvent and Electro- Scratch Factors Tumbling Clearing Degreasing Degreasirg Degreasing Cleaning Pickling Brushing centrifugal torches conveying deoreasing may acid polishing wheels and spraying machines and heat used lathes equipment (drums) stars, slugs, shot multiflame with solvent mixed acids; see polishing materials) chemicals torches flash point with suitable solutions pickling lathes; see and soaps over 100° detergents, Vill seratch brush treatment. Size and Shape Maximum Generally thin All shapes All shapes parts, Limitation pieces. castings all sections; and sizes parts and sizes for interstices sizes except for production large work not used after machining Usual subsequent after Painting Painting Plating Alkaline Painting operation pickling pickling cleaning Painting Polishing Painting cleaning, polishing, Surface and Stress relief may Removes change metal surface. Removes Removes Removes Metal Removes dirt and dirt and greases, and removes dirt dirt, vege- oxides and Dimensional changes. table, and scale oils temperature hotwaterat 200°F temperatures required required none Fire Safety hazards, Safe hazardous Very slight Fairty safe None None None welding oxide and scale too heavy and grease and solid mineral oils ard dirt and prints Subsequent oxidation Yes* Yes* Yes* Yes* Yes* Yes* May given protective treatment, discussed foregoing explanation. THE IRON AGE, September 1945—75 eon tee Chromium TABLE | cleaning and drying problem. Either scouring-action cleaning procedure, electrolytic cleaning procedure often required obtain the best surface conditions with some the zine diecasting alloys. Other pe- culiarities zine are: (1) Its soapy nature does not pre- sent the ideal surface for “paint” ad- hesion, therefore the metal must given special treatments, noted table XXV. (2) The degree corrosion resist- ance the coatings these alloys also dependent the metal being rapidly dried before coating treat- ments well after, therefore forced drying, infra-red lamp drying, drying with sawdust, dip the organic water-soluble solution used for rust prevention steel. Data the cleaning and pickling other metals such stainless steels, Monel, nickel, silvers, magne- sium, noted tables the subject. Pickling Specifics metal pickling solutions and procedures are presented table Practically all acid pickling baths should employ acid inhibitors, par- ticularly the pickling baths for steel. The Navy Specification 51-1-2 require acid inhibitors free-rinsing, non-foaming and non- TABLE toxic. The standard acid inhibitor Diortholythiouria. acid pickling the control the acid concentration and/or other con- stituents required and the control the operating temperature very important, for general, every 17° rise temperature increases the action approximately five (5) times. The control the temperature may require cooling and heating coils and thermostatic control. Electrolytic pickling steel more effective than immersion pickling, though for many applica- tions the latter procedure suffices. Also, indicated previously, the use forced-spray pickling presents bet- ter results. TYPICAL ACID PICKLING AND BRIGHT DIP TREATMENTS Temperature, Treatment Metal Time, Min Application Aluminum............ Nitric acid solution (10 pet Reom Removing smut after alkali dips parts nitric acid and part hydrofluoric acid............. Room alkali dips and Various proprietary acid room, Still baths and baths for pickling elevated and deoxidizing pet sulphuric acid, pct cream tartar and gal water......... 125 Brightener Copper and gal sulphuric acid and gal 150 180 1to scale Copper and gal sulphuric, gal nitric acid, zine sulphate, gal 100 Excess sulphuric Excess nitric and gal gal nitric acid, and gal water............... Room Removal scale pet pet chromic acid weight pct sulphuric 150 Oxide removal Nickel-silvers parts part nitric acids and quantity water. Room Brightener pet 18-8 pet ferric sulphate (ferrisul) pct pet hydrofluoric acid Chrome parts acid, sodium chioride and water............ 140 160 Loosens scale Chrome parts hydroehioric and nitric acids, 100 parts water. 140 160 Removes scale and pet nitric, pct acids and hydrogen Room Brightener —do not use prior plating Zine and pet pet nitric acid, chromic acid with 0.1 hydrogen TABLE ELECTROLYTIC PICKLING Current Density, Nickel and Sulphuric and phosphoric acids and water, varying concentrations....| Varying Anodic varying temperatures (brightener) follow with dip sodium cyanide solution pickling for scouring Steel andiron......... Ferrous suiphate .4N FeSo,) and 0.3 pct acid............ Anodic (brightener) Steel andiron......... Sulphuric acid 47.5 per liter, acid, sodium IRON AGE, September 1945 mov app tive app! sanc pick ket salt burr Sanc face tion must soap sion, effect value clean scour tive the muse with Na,O minu brass Na,O attac show: prese dium lower soda The purpose pickling re- move scale and oxides and for most applications not only very effec- tive but presents inexpensive approach compared tumbling sand blasting. comparatively new type pickler (Kolene) now the mar- ket for deoxidizing and descaling. particularly effective cast iron salt bath and operates about 500° electrolytically. Tumbling, Sand Blasting Castings are often descaled and de- burred means tumbling re- volving drum. (See table XIII.) Sand blasting particularly suitable rough sand castings. metal cleaner must contain: alkalis. (2) material that lowers the sur- face tension. (3) water softening agent. (4) substance cause floccula- tion (dirt suspension). (5) The combination substances must easily rinsed. The Alkali Content forms soap (sa- ponifies) with free fatty acids, the soap turn lowers the surface ten- sion, i.e., increases the wetting ability the cleaner. The factors the alkali which control its ability clean effectively are, the percentage free Na,O and the pH; the higher these values the greater the dirt removing power, The relative Na,O percentages cleaners represent the comparative scouring ability, much like the rela- tive stiffness the bristles scrub brushes. The values represents the force and analogous the muscle power put behind scrub brush. electro-cleaners greater conductivity obtained solutions with higher percentage free However, cleaning zinc, tin, alu- minum, and electrocleaners for the brasses, alkali cleaners with lower and less percentage free Na,O must used avoid excessive attack these metals. Table shows the relative values the al- kali factors. Wetting Power and Rinsibility— Several proprietary wetting agents present great wetting power and ease rinsing. Polymerized phosphates, tetrasodium pyrophosphate and so- dium silicate, the order named, also lower the surface tension; caustic soda and sodium carbonate are in- effective wetting ability. While soap good wetting agent may react with the and magne- sium salts ordinary water form precipitates which are difficult rinse. oils may removed al- containing wetting agents and detergents; however, the solutions are usually operated hot and the heat tends remove some the mineral oil before emulsified. The un-emulsified floats the top the bath and may recontami- nate the metal upon its withdrawal. Water Breaks generally result from films mineral oil soap fatty acids, which are more apt indi- fore momentary anodic operation should follow remove the film. and Saponification the ability suspend dirt and dis- perse oils solution. Sodium meta- silicate good flocculator and has scouring action well serving stabilize the saponified (emulsion) oils and greases. The and the re- duction surface tension are the factors saponification emulsifi- cation. essential start with bal- anced formulations and equally neces- sary maintain reactions, some ingredients are expended more quickly than others; hence proprietary com- cated following acid dip. More thorough rinsing remedy al- ternate hot and cold rinses for the elimination water breaks. Alloys copper and zinc are par- ticularly susceptible water breaks when cathodic cleaning used, there- pounds offer more certainty than shop preparations. Table Spot Test Identification Metal Surfaces. Table II: Accelerated Thickness and Porosity Tests Plated Surfaces. Table III: Salt Spray Resistances TABLE CUTTING AND DRAWING OILS AND THEIR SOLVENT REMOVAL (Recommended Types Cutting Fluids: Independent Research Committee Cutting Oils and Prof. Boston, University Michigan). Nonferrous Metals (Except For Most Ferrous Magnesium Light Machining Operation Metals Mineral Oil, Similar Kerosene) (S) Sulfurized oils (ML) mixture *Soluble olls used for AISI steels Nos. 1110, 1115, 1117, 1118, 1120, 1132, 1137, 1022, 1016, 1116 1111, 1112, 4023, 4027, 4119 and 0.35 carbon content cast stainless Sulfurized oils for AISI steels Nos. 3360, 100, 18-8 austenitic stainless steel, manganese steel, steel, tool carbon). High-speed steels, high-carbon, high-chromium too steels. Remove mineral oils the sulfurized, chlorinated mineral-lard oll types with either hydrocarbon solvents emulsifiable hydrocarbon solvents with chlorinated hydrocarbon solvents. not use anodic alkaline clean- ing any metal when cutting oils are used. Soluble cutting oils may removed with mineral not remove with emulsifiable mineral solvent cleaners. Drawing compounds are mainly soluble oils. Mineral solvents when loaded with greases and oils may distilled with approximate loss pct solvent. Lacquer solvents may also recovered the same manner. For those who not have sufficient volume solvents warrant operating still, number contract plants are located indus- trial areas, and the use such service may result economy. These solvent recovery plants follows: American Chemical Service, Industrial Road, Hammond, George Booth, Robinson St., North Tonawanda, Y.; Brace Engineering Co., 547 Belmont St., Indianapolis; Condor Solvents, 4ist New York City; Dibble Color Co., 1497 Grand Boulevard, Detroit (lacquer thinners only); Dorward Son Co., 260 California San Francisco Eastern Refining Co., Wallingford, Conn.; Franco-American Chem, Works, J.; Leon Finch, Ltd., 728 59th Los Angeles; Hammond Chemical Service, 241 Brunswick St., Hammond, Ind.; Industrial Reclaimers Co., 2827 Fort St., Detroit; Laboratories, Ann Arbor, Mich.; National Aluminum Co., West College St., Los Angeles; Nord Co., 868 Broad St, Newark, J.; Solvent Process Co., 3540 Emery Los Roblyn Oil Co., 70-88 Freeport St., Boston; Allen Rogers Corp., Cooper Ave. and Dry Harbor Glendale, New York; Solvents Recovery Service, 446 Eucalyptus Ave., Los Angeles; Solvents Recovery Service, Glendale, Y.; Solvents Recovery Service, 1019 Broad Newark, Chemical Co., 15444 Nine Mile Road, East Detroit; Universal Sol- vents Co., Live Stock Exchange Bidg., Kansas City. THE IRON AGE, September TABLE FACTORS ALKALI METAL CLEANING Value pet Solution Alkali 20°C 20°C Caustic soda caustic and pct metasilicate (granular) Sodium sesquisilicate 12.7 13.5 Tetrasodium pyrophosphate orax (Modified soda) carbonate soda; sodium acid Value pet Amp Per Ft, Comparative Conductivity 6v-4 per gal Concentration 0.32 Per Gal, Grams, Weight, Less Per addition one the various proprietary organic inhibitors and some cases wetting agents (as well agitation) restricts (1) hydrogen embrittlement, (2) excessive attack metal, and (3) saves acids, and (4) prevents great extent. Hydrochloric acid pickles not cause hydrogen embrittlement the extent that sulphuric acid pickles. Newer developments pickling are the treatment steel chlorine vapors for the removal light scale, and the treatment cast iron for the removal silica and scale molten bath Kolene, proprietary compound tem- Oxidation occurs metals following pickling and alkaline cleaning rinses upon drying, especially when hot water rinses are used. Proprietary water-soluble compounds may used the rinses, which will inhibit oxidation. The inhibited surface may painted upon, may removed water rinse when the metal plated. TABLE TYPICAL IMMERSION CLEANING SOLUTIONS Temperature Metal Chemicals Per Gal Water Operation Aluminum pct pct caustic soda 120 150 Steel tank. Very coarse pet pct caustic pct Room etch, very irritating fumes added obtain etch Aluminum Mixtures milder alkalines with 150 200 Steel tank. Fine etch, inhibitors generally well com- comparatively little attack pounded proprietary brands metal Brass and copper Ferric alse same steel 200 Steel tank cleaners Cadmium 300 per liter ferric chioride 150 180 Lead-lined tank 100 per liter copper sulphate liter water Cadmium 200 per liter chromic acid 150 180 Lead-lined tank per liter water Steel High concentration caustic soda 200 Steel tanks sodium silicate Steel parts sodium metasilicate Steel tanks Steel sodium carbonate Steel tanks soap 0.1 wetting agent Tin sulphate and mild alkaline Steel tanks Zine 3.5 sodium chromate with chromatizing dip, tank Zinc tri sodium phosphate 150 200 Follow with chromatizing sodium carbonate dip, steel tank caustic soda copper sulphate acid Room Follow with chromatizing 6.4 gal water Magnesium pct caustic soda other strong 200 Steei tank—follow dip caustic solutions chromic acid solution pet with 0.5 pct sulfuric See Avens patent table Chromic acid, phohsphoric acid solution for deoxidizing prior spot welding aluminum; also certain proprietary acid solutions. Many effective proprietary compounds are marketed accomplish im- mersion cleaning. When difficulties are encountered with standard formulations well investigate the claims cleaning compound manufacturers. Dilute acid dips phosphoric, acetic sulfuric acid suggested following alkaline cleaning prior final rinse. 78—THE IRON AGE, September 1945 various Thicknesses Electrode- posits. Table IV: Electrolytic (Galvanic) Corrosion Factors. Table Atmospheric Exposure Tests Electroplated Metals. Table VI: Comparative Frictional Properties Metal Surfaces. planation Charts VII XII. Table VII: Comparisons Pickling, Degreasing, Cleaning Procedures. Table Typical Acid Pickling and Bright Dip Treatments. Table VIIIB: Electrolytic Pickling. Electrolytic Pickling Data. Table IX: Cutting and Drawing Oils and Their Solvent Removal and Solvent Recovery Contract. tillers. Explanation Chart Table Factors Alkali Metal Cleaning. Table XI: Typical Immersion Clean- ing Solutions. Table XII: Typical Metal Cleaning Operations. The following tables will appear the issue Sept. 13: Notes Electropolishing. Table XIII: Barrel Deburring, Pol- ishing, Buffing. Table XIV: Polishing Wheel Typi- cal Operation Data. Table XV: Operation Comparisons Polishing and Buffing Wheels. Table XVI: Typical Polishing Grit Table XVII: Scratch Brush Opera- tions for the Removal Burrs and Seale. Notes the Selection Sur- face Finishes for and Decorative Purposes. Table XVIII: Physical Character- istics Electrodeposited Coats. Table XIX: Physical Control Plating Solutions. Table XX: Solutions for Stripping Electrodeposited Céats. Active Total Solution Tin Aluminum Trisodium 18.0 12.0 12.9 3.76 15.65 12.0 | | | 4 | | i ser on ing TABLE TYPICAL ELECTROLYTIC CLEANING OPERATIONS Current Density Treatment Typical Electrolyte Amp Per Temperature Time, Operating Metal (Per Water) Volts Min Data Brass Mild alkaline solution 200 Cathodic, anode, and tank Brass sodium carbonate high 175 200 Few seconds Cathodic, anode, and tank nickel plated tri-sodium phosphate sodium phosphate caustic soda and tri-sodium phosphate 212 solution and NaCi Magnesium 250 per liter chromic acid 150 500 113 Few seconds Cathodic, lead anode 150 per liter sulphuric acid Magnesium pct hydrofluoric acid 400 Room Cathodic, anode and tank Magnesium pet pct) 400 Room 1/6 Cathodic, lead anode and tank acetic acid Magnesium 7.5 sodium carbenate 216 140 Cathodic, lead anode and tank tri-sodium phosphate 195 0.2-1.0 ammonia baury! sulphate Nickel sodium 210 Cathodic, lead anode and tank, follow sodium sesquisilicate pet acid dip 0.5 caustic soda sodium carbonate 120 Cathodic, anode and tank, follow pct sulphuric acid dip Nickel Patent 2,299,054 Sodium cyanide cathodic Steel sodium carborate 170 200 Steel anode, brazed copper bars phosphate caustic soda 0.5 caustic Zine 0.5 tri-sodium phosphate 160 Cathodic, follow dip 200 per 1.2 sodium 180 liter chromic acid 212° caustic soda sodium dichromate STEEL: Anodic cleaning preferable except removing drawing compounds which chlorinated hydrocarbons exist. ALUMINUM AND ZINC are never cleaned anodically. NICKEL PLATE not cleaned electrolytically prior chromium plating due passivity created electrolytic cleaning. Many proprietary electrolytic cleaners are offered. interesting approach metal cleaning new development called Kolene which makes use fused salts temperature range between 850° 950° and utilizes reverse current procedure operation amp per ft. claimed that Kolene removes silica and carbon from cast velopment cathodic cleaning fused caustic soda. The following tables will pre- sented the issue Sept. 20: Table XXI: Key Numbers Data the Regulation Baths for the Quality Control Deposits. Bath Regulation Data per Key Numbers. Data Proprietary Baths. Table XXII: Surface Treatments Aluminum Alloys. Table XXIII: Surface Treatments Magnesium Alloys. Table XXIV: Typical Metal Etch- and Embossed Metal ata. Table XXV: Immersion Treatments for Increased Corrosion Resistance, Paint Adherence and Appearance. Production Painting Dye Coloring Metals. Table XXVI: Government, Army and Navy Specifications Zine Chro- mate Primers. Table XXVII: Comparisons Physical Factors Few Synthetic Lacquers and Infra-Red Drying Data. The following tables will appear the issue Sept. 27: Table Comparative Data, Army and Navy Specification Lac- quers and Enamels. Table XXIX: Comparisons Con- (To continued next week.) iron effectively. Another new cleaning and pickling de- vection and Radiant (Infra-Red) Dry- ing Explanation Chart Table XXX: Comparative Drying Time Colored Lacquers Infra- Red Lamps. Table XXXI: Tinting and Hiding Power White Pigments. Table XXXII: Luminescent Coat- ings. Surface Designation the American Standards Association. Table XXXIII: Typical Preserva- tives (Rust Preventives). Table XXXIV: Devices Relative Metal Surface Testing. THE IRON AGE, September 1945—79 de- ure nal ng, ing and etal and Sur- and ster- for Trepanning Welded Joints destructive type test and covering small areas, valuable welding inspection tool for revealing cer- tain critical defects not detectable other methods. the experi- ence Calship, the combination trepanning and X-ray appear the ideal inspection procedure. Interpretation photographs plugs removed from welds trepanning can readily done welders average skill. soundness and quality welded joints, visual inspection not enough. Therefore, some method must used which will tell the condition inside the joint. Several standard methods are avail- The selection the best method used depends the information required and the use such informa- tion. Calship the following informa- tion was desired minimum cost, the shortest possible length sence defects such slag, gas pockets, lack fusion, cracks, lack penetration, etc. (2) Plate edge preparation for weld- ing. (3) Fitup the two members prior welding. (4) Procedure welding, i.e., weave stringer beads, type and size electrode, etc. (5) Examination the plate stock for segregations and liminations. This information when accumulated should serve inspection control welding and fitting quality cer- tain joints, and broader sense for the analysis welding practices and Calsk consi (1) (2) able. However, each has its limita- tions, advantages and disadvantages. time: (1) Soundness the weld, i.e., ab- procedures. The information could serve educational and informa- tional media for the operator well for supervision and management. may serve permanent record the welding each unit and hull, that comparison could made supervision, welding operators, pro- cedures, and also locate common difficulties specific joints. case defects, could used for the determination and fixing craft re- sponsibility (fitters, burners, chippers, welding operators, etc.). comparing inspection methods for these ends, some the advantages and disadvantages the trepanning procedure come the fore soon enough. Unlike destructive type test. But simple and does not require expensive Plugs can removed from the welded joint unskilled labor. These plugs after etching and photographing can used tell the complete story the one spot. With the minimum accompanying explanation, the welder can learn from the photographs the fitup, the plate condition, the preparation and procedure the weld. distinct dis- advantage trepanning that Fig. required for taking out plugs from welded joints. q q 4 (5) covers small area compared with Xray, for example, which can used cover considerable linear length con joint, ranging from in. in. the ultimate perfection 80—THE IRON AGE, September 1945 weld these =< for Defects ARTHUR Testing Engineer, And MacKUSICK Weiding Engineer, California Shipbuilding Corp., Wilmington, Calif. weld quality inspection required, combination the several inspec- tion techniques mentioned above will necessary. However, analyzing these methods was felt that tre- panning was more suitable for use Calship due the following major considerations: (1) Certain critical types defects are not detectable except tre- panning. (2) Plate edge preparations, fitting, cannot suitably and definitely determined after the joint completed, except through trepanning. (3) Steel stock used cannot checked for defects such lam- inations and segregations the use any method other than tre- panning. (4) Photographs are easily made trepanned plugs and serve the purpose ideally, far edu- cation various personnel in- volved unnecessary. ex- tremely vivid picture all con- ditions involved available. There tion. (5) Cost cheaper trepanning than making Xray gamma ray shots. cost survey was made the yard and then checked elsewhere heavy in- dustry such shipbuilding, pres- sure vessels, and verifies this lower cost. This lower cost covers cost repair holes after re- moval plugs. order familiarize others who may interested the use the trepanning method for inspection and control welding, the following sys- tem and procedure used Calship, outlined: The locations test plugs the various joints were selected com- mittee all interested persons and agencies. These locations, are chosen cover the following critical spots the ship: (1) Erection butts sub-assembled sections—shell and decks. (2) Tank joints. (3) Welded joints the critical stress points the ship, i.e., in- 2—Sawing out plug. pry helpful maintain steady pressure case horizontal trepanning. cluding sub-assembly welded joints such locations. The test plugs are marked off daily line with welding completion the joints each unit involved. Test plug crews then take the plugs from the locations marked. Procedure actual machining out the plugs, preparation for examination, repairs, now outlined: Equipment required, (see fig. 1,) consists the following: (1) “F” size drills. (2) %-in. electric drill for pilot hole. (3) heavy-duty electric drill for saw and countersink. (4) Arbor. (5) Hole saw, in. diam. (6) reamer with 45° taper. (7) Midget air chipping gun. (8) Specially tipped chisels. The following the sequence operations for taking out test pluy from weld: (1) Drill pilot hole using size drill. (2) Use special tempered guide arbor, diam. (3) Start sawing with dull saw prevent breaking teeth, and groove deep using guide. (4) Replace worn saw with sharp one. Remove guide and continue through the material. (5) pry bar “old man” may used maintain steady pressure overhead horizontal trepan- ning (Fig. 2). (6) When sawing flat position, air can used keep cuttings cleaned from around the saw teeth. Cuttings clog saw causing excessive heating and binding. THE AGE, September 5. re- ing Section 3—Special steel chipping chisel for removing broken saw teeth when tre- panning weld test plugs. case tooth breaks off and be- comes clogged the groove, chipping tool shown fig. can used midget shipping gun dislodge the teeth. (7) flat trepanning, the plug, after being removed from the plating sometimes falls out the saw before the operators get it. overcome this difficulty tool shown fig. was devised serve continuous guide until the operation complete. The clips fly out under centrifugal ac- tion. can seen that the plug will fall against the “butterfly” and will not drop out into the compartment below. Another type the slotted “spring” type also shown. The butterfly type more satisfactory. facilitate repairs, after re- moval the plug, the hole countersunk using in. reamer with 45° taper countersinking RIGHT 5—Steps the preparation the plugs for examination, showing plug within 3/16-in. bottom the hole, thus leaving 3-/6 in. land. fig. shown the plug vari- ous stages preparation. the left side the plug shown as-tagged and from the ship. Second from the left the plug down the lathe. Third from the left shows stencil identification the edge, while the picture the right shows the plug polished down and etched. The procedure for examination preparation follows: (1) Face down the plug lathe direction perpendicular the line weld. (2) Stencil identification edge plug. (3) Polish plug water belt sander. (4) Etch with iodine solution and then with ammonium persulfate solution. (5) After taking photograph both sides magnification, cover etch with glyp