E S T . 1902 T R A D E J O U R N A L
IRITISH IOULDING
IA C H IN E C ° LTD
W ITH WHICH IS INCORPORATED T H E I R O N A N D S T E E L T R A D E S J O U R N A L
V O L . 73. N o . 1460. A U G U S T 10, 1944 pin*!«.C? pt td‘, ,By
_ r , , , A n n u a l S u b s c r i p t i o n , Hi
R e gH lere d at the C.P.O . as a N e w sp a pe r Offices: 4 9 W e llin g to n Street. Strand, lonaon, W . C U . i (_a n j O v e r s e a s , 21 !• ( P re p i
IN V E S T IN
ÎAVERSHAM, K E N T . BOXES
S T E R L I N G F O U N D R Y S P E C I A L I T I E S L T D . . B E D F O R D
M A N S F I E L D MOULDING SANI
• P U L V E R I S E D R E A D Y F O R U S E I F R E Q U I R E !
A L B I O N (M a n sfie ld ) S A N D C O . xSoi' W. WARDLTO; Albio" Works, SHEFFIEL
Te le p h o n e s: S b H f i o W 2 6 3 1 1 (15 lin o s ) M a n s fie ld 37
N E T T L E E l e c t r i c F u r n a c e C r c u / t i l t i n r o w s w i t h S t a n d a r d S h a p e s
The use of “ N E T T L E ” ( 4 2 / 4 4 % A lu m in a ) F ire b ric k in Electric A r c Fu rn ac e c ro w n s has been sta nd a rd practice w ith c e rtain firm s fo r a c on sid e ra b le time. C om p a re d w ith Silica b ric k “ N e t t l e "
his the a dvantage o f b e tte r sp a llin g resistance and lower c ost— the fo rm e r p o in t o f special Importance in to p cha rged o r in te rm itte n tly worked furnaces.
The “ C up o la -En d A r c h ” c ro w n illustra te d is pilt with three m a chine m ade sh a p e s— a s p rin g e r;
Hide arch for the e le ctrod e rin g s ; and a c up ola - (nd arch for the b o d y of the c ro w n . It is being
¿opted by an inc re a sin g n u m b e r o f c u s to m e rs iho find its use e c o no m ic . C o m p a r e d w ith o ne Juilt with large spe cial sh a pe s th is c ro w n has the
Plowing a dvantages ;—
D e n s e r te xtu re . B e tte r sha pe and size.
Q u ic k e r d e liv e ry .
L o w e r cost. o f the L a r ro n Com,
O H N O S T E I N & C O . L T D . B O N N Y B R I D G E . S Ç O T L A N
I hurtner p a rtic ula rs w ill be su p p lie d on request.
T E IS E N
e n a m e l l i n g m u f f l e s .
P n e u l e c C U P O L A S
THE CUPOLA W IT H TU YERES PLACED B E LO W IN STE A, OF IN SID E THE BEL
U A K A
Built by
P N E U L E C L T D ., S M E T H W I C K , N r . B I R M I N G H A I
CARBORUNDUM COMPANY LT.P
T R A F F O R D P A R K :: M A N C H E S T E R
O U N D R Y T R A D E J O U R N A L 3
S p e rm o tin ltd~|
H A L I FAX. Y O R K S
I n my designs it w ill be possi
ble to work out a casting o rjo r g in g that w ill weigh pounds instead o f hundredweights, or ounces instead o f pounds. In this way the lig h t alloys that have been developed under the stress o f war are destined soon to lighten the machinery o f life in every direction— so that industry, transport, ( and, we hope, international relationsJ w ill benefit.
That is one o f the reasons why we are so proud to be makers o f alum inium alloys f o r every conceiv
able purpose.
■— S L O U G H , B U C K S V \ Y|
T E L E P H O N E : S L O U G H 2 3 2 1 2 J I M | « \ J a W IR E : Ï N T A L L O Y D S L O U G H
!
A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L
M o r r i s
mechanization
H erbert M orris Lim ited L o u g h b o ro u gh England
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1
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f f f G o r / 4 r £ 4 iv J o • r / w p ° « r 4 « r /.
l l f fc l L / / A
C0NTRAcr
J m m m P / # n \ t
N o m a tte r h o w g o o d j o b M rs . M o p p m a k e s o f th e c le a n in g y o u w o u ld n ’t e x p e c t h e r to c a rry o u t im p o r t a n t n e g o tia tio n s . M u c h th e sa m e a r g u m e n t h o ld s g o o d w h e n it c o m e s t o s a fe ty m e th o d s a n d sa fe ty dev ices.
S a fe ty is a j o b f o r a n e x p e rt if e v e r th e r e w a s o n e b u t e v en a n e x p e rt n e e d s t o k n o w th e fa c ts. T h a t ’s w h y w e lik e t o visit y o u r f a c to r y , o r w o r k s h o p a n d s tu d y y o u r p r o b le m a t firs t h a n d .
I f y o u ’r e in te r e s te d in s a v in g y o u r w o r k p e o p le a lo t o f g r ie f a n d w o e a n d a v o id in g th e w a s ta g e o f p re c io u s m a n - h o u r s w h y n o t ca ll u s in a n d b e
On th e s a fe sid e ? f Designers oj
Industrial Safety
S
K% Devices.afety P ro d u cts ltd I
Respirators, Helmets,Welder’s Goggles with Protex Lenses, etc.
U . S . A 44 HATTON GARDEN - LONDON E.C.1
Sole distributors in Great Britain Jot
W I L L S O N P R O D U C T S I N C . O F R E A D I N G , P E N N .
G E O R G E G R E E N & C O .
Foundry Equipment Engineers & Contractors
K E I G H L E Y , Y O R K S .
(E s t a b lish e d 1900)
T e le g r a m s : “ C u p o l a , ” K e i g h l e y . T e le p h o n e : 2 5 1 8 K e ig h l e y .
Iron, Steel and Brass Foundry Melting Equip
ments are our Speciality
C U P O L A S , S T E E L C O N V E R T E R S , C R U C IB L E A N D N O N - C R U C IB L E F U R N A C E S , C U P O L A C H A R G I N G M A C H IN E S , H O IS T S , M O T O R F A N S , L A D L E S , S A N D M IL L S A N D SIFTERS, R U M B L E R S , PIG IR O N B R E A K IN G M A C H IN E S ,
R O T A R Y C O R E M A C H IN E S , ETC.
f o u n d r y t r a d e j o u r n a l 7
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for
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o ni r o n C A S
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C O N C E N T R A T E D O N T H E P R O D U C T
Complete concentration on every detail of manufacturing process from the raw material stage to final inspection makes Armstrong W hitw orth products stan
dards of excellence, supreme in their field
b A 1M 1TH O *« V .M IT W W T H »
«IMtTlOMO WHITWOtTW • CO. f»**> I TO.A R M S T R O N G W H I T W O R T H G A T E S H E A D
o nTY N E
GREAT W E S T E R N W O R K S • SMALL HEATH • BIR MIN GHAM II
Lo n d on O ffice 2,QUEEN A N N E S GATE , W E S T M I N S T E R , L O N D O N S . W . 1 STEEL CONVERTERS
CHARGING MACHINES
MOULDING MACHINES
C U P O L A S • F A N S
R O O T S • B L O W E R S
S A N D M I L L S • ETC .
A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L 9
S C R E E N A R A T O R
F O R R A P I D S A N D C O N D I T I O N I N G
K N O C K - O U T B A R
F O R S M A L L M O U L D S S A N D
D I S C H A R G E S P O U T (A N G L E A D J U S T A B L E )
P U S H B U T T O N S W IT C H
F E E D I N G H O P P E R
I M P E L L E R C A S IN G D U S T P R O O F
★ P o w e rfu l g yro -recip ro catin g m otion of riddle.
★ D riv in g gear totally enclosed.
★ S tu rd y construction throughout.
★ P u sh button electric control.
★ C le a n s, aerates, and d elivers sand clear of m achine.
★ A n efficient labour-savin g unit.
F O U N D R Y P L A N T & M A C H I N E R Y L T D .
113 wg l a es g o w STMr. Huntsman pulls a tooth.
B enjam in H u n tsm an (1704-1776), the In v en to r o f C rucible C ast Steel in its present form , w as a rem ark ab ly shrewd, ob servant and practical m an. S tartin g as a C lo ck m ak er a n d M ender in D oncaster, the co n stan t breaking o f English springs led him to m an u factu re his ow n steel, w hich later becam e his w hole o ccupation. In ad d itio n , it is reco rd ed o f him th at he practised Surgery w ith dexterity, an d was held in special esteem as a n O cu list;
he was alw ays read y to give advice in surgical cases, a lth o u g h he alw ays declined paym ent. H is skill was alw ays a t the disposal o f his w o rk p eo p le an d o n e m ay
¡magine th at m any a n aching to o th was p rom ptly disposed of.
B R O C K H O U S E C A S T IN G S L IM IT E D p roduce steel castings to all com m ercial specifications, specialising in h e at resisting steels p ro d u ced by th e m o d ern equivalent o f the H u n tsm an process. R ecent developm ents have led to the actual casting of Ships ’ C hains a n d C able, an interesting castin g technique w hich we shall be pleased to explain to you if you are interested.
CASTINGS IN STEEL
BROCKHOUSE CASTINGS LTD.
WEDNESFIELD, WOLVERHAMPTON
T elephone - - F allings P a rk 31221
Ships’ Cable cast in m ild steel, proof load test o f 134 tons, by B ROCKHOUSE CASTINGS
LIM ITED
DRY TRAD E JO U RN A L II
. . . for trial heats and ex per ime nta l w o r k . . .
the E F C O high frequency furnace . . . ideal for m elting special heats o f copper, alu
m inium , bronze, brass, iron, steel, nickel, silver, gold, platinum , iridium , palladium, rhodium , etc., etc.
Furnace Capacities : 4 ozs. to 40 lbs.
Spark Gap Converters : 3 to 35 K.V.A.
Electronic Equipment : 1 to 50 K.V.A.
Motor Generator Sets : 10 to 45 K.W.
Larger sets for production output.
These furnaces may be used fo r melting in vacuo or under inert atmosphere, fu l l technical in f ormation from ;
ELECTRIC FURNACE
CO. LTD.
N E T H E R B Y , Q U E E N ’S R O A D , W E Y B R I D G E , S U R R E Y T e lep h one : W e yb rid g e 3891 Te legra m s: Electrifur W e yb rid ge
P h o to b y c o u rte sy o f M e s s r s . M a r s h a l l & C o ., L td ., G a in sb o ro u g h
DIMENSIONAL ACCURACY & CLEAN STRIPPING
C L E A[N stripping enhances the appearance o f a Casting, and mini
mises fettling costs. Apart from these considerations, a clean skin is o f great importance when a Casting encloses highly finished transmission gearing. A Casting with traces of burnt-on sand adhesions may be put into service, and in due course, the sand becomes detached, with fatal results to the life o f the mechanism.
The above photograph shows a Casting, together with the assembled mould and cores. It is a gear case for a well-known Road Roller, transmitting a considerable drive. Maximum machining allowance is A in., and most o f the finishing is done
by grinding. Clearances between the gears and the Casting are extremely fine, and this requires a high degree o f dimen
sional accuracy, besides a clean skin.
G.B. Kordek is employed in all cores, and first class results are obtained with semi
skilled labour, in combination with a very efficient system o f management.
K o r d e K products
f o r O IL SA N D • FA C IN G SAND G R EEN SAN D • D R Y SAN D • SKIN D R YIN G • LOAM FA C IN G • CO RE JO IN T IN G • M OULD W A SH ES ■ Etc.
K o r d e K — G.BK O R D E K — G.B K o r d o L
G. 6. K o rd e k & G. 8. K ord ol a re m a nu fa cture d u nder B ritish Letters Pa tent N os. 5 1 5 4 7 0 , 5 4 3 2 0 2
C O R N P R O D U C T S C O . , L T D . , 3 5 6 - 6 0 O X F O R D S T R E E T , L O N D O N , W . l
A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L 13
e c o n o m i c a l
A i r l e s s S h o t b l a s t i n g !A N D E F F I C I E N T ________________________________________________________9 _
A 90-in. diam. Table Ty p e S A N D W I Z A R D Airless Sandblast Machine with Dust Extraction Plant.
Also made in Rum bler Type in a range of sizes.
THE
T e le p h o n e :
M ID Ia n d 4 7 5 3 -4
( o n s i r u c i i o n a I
V - > E N G I N E E R I N G C ° U S
T I T A N W O R K S , B I R M I N G H A M , 12
T e le g r a m s :
“ S T R U C T U R A L "
W O R L D F A M O U S
FOR HIGH Q U A LIT Y AN D Q U IC K DESPATCH IDEAL FOR NON-FERROUS METALS
TELEGRAPH OR TELEPH O N E
M A N SFIELD S T A N D A R D
G O L D M E D A L
M A N S F I E L D S T A N D A R D ■ ■ a m
sand co lie M O U LD IN G S A N D
M A N S F I E L D ,
E N G L A N D . P U L V E R I Z E D O R U N M I L L E D A S R E Q U I R E D T E L . 201— 2
B a l l a r d Core D r y in g Ovens
SHELF TYPE • D RA W ER TYPE • BOGIE TYPE
made any size to suit requirements
GAS or COKE FIRED W ITH or WITHOUT FAN CIRCULATION
C O N T IN U O U S T Y P E CORE O V E N S M A D E B Y S P E C IA L IS T S I N C O N T IN U O U S O V E N D E S IG N
A L L T Y P E S including
F. J. BALLARD & CO. LTD., T IM P A L E • TIPTON » STAFFS.
P h o n e: T IP T O N 1281-3A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L 15
Sh o t B la s t F e a tu re s— N o . 3
ACCESSIBILITY
A n y user of Shot Blast Plant realises that maintenance is inevitable, but it can be reduced to a m inim um w h e re w o rk in g parts are sufficiently accessible to ensure regular inspection.
★ J u s t another reason why Spenstead is preferred
SPENCER £ HALSTEAD P
O S S E T T , Y O R K S ;
T e le p h o n e t O s s e tt ¿63-4
L O N D O N : 2 2 O L D Q U E E N S T ., W E S T M I N S T E R S . W . I R U G B Y : 17 L A W F O R D R O A D
G L A S G O W : 6 0 S T . E N O C H S Q U A R E , C . l
WITH WHICH -K INCORPORATED TH E IR O N A N D STEEL TRADES ¡O U R N A L
49 , W e ll in g t o n Stre e t, L o n d o n , W . C .2 .
W A R T I M E A D D R E S S to w h ic h all c o m m u n lc a t lo n s s h o u ld be se n t I__
3, A m e r e h a m R o a d , H I G H W Y C O M B E , B u c k * . 'G r a m i i “ Zacate cas, H ig h W y c o m b e . "
•P h o n e I H I G H W Y C O M B E 1792 (3 lines).
P U B L I S H E D W E E K L Y I 21s. p e r a n n u m ( H o m e a nd O v e r s e a t )
O F F I C I A L O R G A N O F I
C O U N C I L O F I R O N F O U N D R Y A S S O C I A T I O N S C h a irm a n I F l t iH e r b e r t W r i g h t , T h e B u tte rle y C o m p a n y , R ip le y , n e a r D e r b y . S e c re ta ry I V . D e lp o r t, 2, C a x t o n Stre e t, W e s t m in s t e r , S . W . I.
P a rticip ating A ssociations I B rit is h B ath M a n u f a c tu r e r s ' A s s o c ia t io n B rit is h Ir o n f o u n d e r s ’ A s s o c ia t io n ; B rit is h M a lle a ble T u b e F ittin g s A s s o c ia t io n ; C a s t Ir o n A x l e b o x A s s o c ia t io n ; C a s t Ir o n C h a i r A s s o c ia tio n ; C a s t l r o n H e a tin g , B o ile r a nd R a d ia to r M a n u f a c tu r e r s ' A s s o c ia t io n ! C a s t Ir o n S e g m e n t A s s o c ia t io n ; G re e n s a n d P ip e F o u n d e r s ’ A s s o c ia t io n o f S c o t la n d ; I r o n f o u n d e r s ' N a t io n a l C o n fe d e ra tio n ; N a t io n a l A s s o c ia tio n o f M a lle a b le Ir o n f o u n d e r s ; N a t io n a l In g o t M o u ld A s s o c ia t io n ; N a t io n a l Ir o n f o u n d ln g E m p l o y e r s ’ F e d e r a tio n A s s o c ia t io n o f A u t o m o b ile a n d A ll ie d H i g h D u t y Ir o n f o u n d e r s ; B rit is h C a s t Ir o n R e se a rc h A s s o c ia t io n (a ffilia te d ); B ritis h G r i t A s s o c ia t io n (affiliated);
F lu s h in g C is t e r n M a k e r s ' A s s o c ia t io n (affiliated) : In s t it u t e o f B rit is h F o u n d r y m e n (affiliated), ______
I N S T I T U T E O F B R I T I S H F O U N D R Y M E N P R E S I D E N T , 1 9 4 3 -4 4 : D . S h a r p e , F o u n d r y P la n t & M a c h in e r y , L t d . 113 W e s t R e g e n t S t r e e t , G la s g o w .
G e n e ra l S e c re ta ry I T . M a k e m s o n . A c t i n g S e c r e ta r y , J. B o lto n Sa in t J o h n S tre e t C h a m b e rs , D e a n sga te , M a n c h e ste r 3.
B R A N C H E S
B irm in g h a m , C o v e n t r y and W e s t M id la n d s I A . A . T lm m ln a , F.I.C . 3 3 C a r t e r s L a n e , Q u i n t o n . B r i s t o l a n d W e s t o f E n g l a n d : A . H a re s, 20 , G r e e n b a n k R o a d , H a n h a m , B risto l. E. M id la n d s I S. A . H o r t o n “ T h r e e , " M o s t y n A v e n u e , L lttle o v e r, D e r b y . L an cs i H . B u c k ley, E lle s m e re . N o r f o l k A v e n u e , B u r n le y . L o n d o n I V . C . F a u lk n e r, 3, A m e r » ham R oad , H ig h W y c o m b e . M id d le s b r o u g h (pro tern.) : J. K . S m ith so n , N o r t h -E a s t e r n Ir o n R e fin in g C o m p a n y , L im ite d , S tlllln g to n , S to c k to n -o n -T e e s . N e w c a stle -u p o n -T y n e i C . Lashly, S i r W . G . A r m s t ro n g , W h it w o r t h & C o . (Iro n fo u n d e r» ), Ltd., C lo s e W o r k s , G ateshe a d Sc ottish i J. Bell, 60, St. E n o c h Sq ua re , G la sg o w . Sheffield : T . R. W a i k e r , M .A ., E n g lis h S t e e l C o r p o r a t io n , L td ., She ffie ld. W a le s and M o n m o u t h i A . S. W a ll , 14, P a la c e A v e n u e , Lla nd a ff, C a r d iff. W e s t R id in g o f Y o r k s h i r e : D o u g la s J e p so n , M .Sc., 9, A m b le s ld e A v e n u e , B ra d fo rd . S o u th A fric a : B. P. S k o k , M u tu a l B u ild in g , J o h a n n e s b u rg .
S E C T I O N S
B u r n le y I H . B u c k le y , E lle sm e re , N o r f o lk A v e n u e , B u rn le y , Lancs.
C a p e ' T o w n : K . Z w a n z U e r , P .O . B o x 346, C a p e T o w n , S. A fric a . East A n g lia n i A . N . S u m n e r . 5 1 6 , N o r w i c h R o a d , Ip sw ic h F a l k ir k : T. R. G o o d w in , " V le w f ie ld , " F a lk ir k R oad , B o n n y b rld g e . L in c o ln i E.
R . W a lt e r , P h . D . , T h e T e ch nica l C o lle g e , L in co ln .
A S S O C I A T I O N O F B R O N Z E A N D B R A S S F O U N D E R S P r e s id e n t : H . B ls se ll, J. S t o n e & C o ., L td ., L o n d o n . S e c r e t a r ie s : H e a th c o te & C o le m a n , 2 5 , B e n n e t ts H ill, B ir m in g h a m , 2
T H E I N S T I T U T E O F V I T R E O U S E N A M E L L E R S P re s id e n t I W . H . W h it t le , W . H . W h it t le , L im ite d , Eccles, near M a n c h e ste r. C h a irm a n I W . T o d d , P a r k l n io n S t o v e C o . , L td ., S te c h - fo rd , B ir m in g h a m . H o n . Sec. i W . T h o m a s , A . I . C , B a n k H o u s e , H ig h S t r e e t, R lc k m a n s w o r t h , H e r ts .
F O U N D R Y T R A D E S ' E Q U I P M E N T A N D S U P P L I E S A S S O C I A T I O N
P re s id e n t I G . E. France, A u g u s t ’», L im ite d , T h o r n T r e e W o r k s , H alifax. H o n o r a r y S e c r e t a r y : K . W . B rid g e s . A s s is t a n t S e c r e ta r y ! M is s L. C o x , 52, S u r b ito n H ill P a rk , S u r b ito n , S u rre y .
W E L S H E N G I N E E R S ’ A N D F O U N D E R S ' A S S O C I A T I O N P re sid e n t i W . E. C le m e n t, C.B.E., M o rf a F o u n d ry , N e w D o c k , Lla ne lly.
S e c re ta ry t J. D . D . D a v is , I, St. Jam es G a rd e n s, Sw anse a.
*“ -■* «läse«
B R I T I S H C A S T I R O N R E S E A R C H A S S O C I A T I O N A l v r c h u r c h , B ir m in g h a m . ’P h o n e a n d ’G ra m a : R e d d l t c h 7 l 6 . S c o i c lih La b o n t o r le i 1f o u n d r y T e c h n ic a l ln » t l t u r e » M e e k ’» R o a d , F a l k ir k . < P h o n * t 3T L I
mrtdn n f raw materials in short supply owing to war conditions are advertised as nn indication that thev are necessarily available for export
S p ira l Conveyor
a nd Vertical Elevator
The clean outline of the tw o
spiral co n v e yo r tro u g h s and the boot of the shot return elevator illustrated herewith are typical of the accessible nature of those parts w hich are so easily forgotten.
The need for all possible conservation o f man power ;
•the demand for the maxim um output o f vital cast metallic products; the insistence upon the lowest cost o f produc
tion ; and the necessity o f maintaining, and even improving, the quality o f those products.
A ll these conditions combine to point to the only satisfactory solution to all these problems—
M E C H A N I S A T I O N
but it must be mechanisation particularly considered, designed and adapted to the individual site conditions ; to the particular product ; and with full regard to all the factors, economic, geographical and human, which may have any bearing on the problem.
In other words consult :—
“ The Specialists in Foundry Mechanisation”
whose products
“ Set the Standard b y which Foundry Plant is ju d g e d .”
’Phones : 6 1 2 4 7 &. 8
HALIFAX , ENGLAND
'G ram s : August, H a l if a x Sole Licensees a n d manuf acturers for British Empire(excluding C a n a d a ) of the Simpson S a n d M ixerFoundry Trade Journal., A u g u st 10, 1944
â stab i/s h ed f $ 0 2
M U I T E F
W IT H W H I C H IS i r K O K r o u r E D T H E I R O N A N D S T E E L T R A D E S J O U R N A L
Vol. 73 Thursday, A u g u st 10, 1944 No. 1460
A Questionnaire on M aintenance
M e m b e rs o f th e S te e lf o u n d e r s ' A s s o c ia tio n o f A m e ric a h a v e , n o d o u b t, fille d in a s m a n y q u e s tio n n a ire s a s t h e i r B ritis h c o n f rè r e s . T h e ir m in d s m u st h a v e b e e n c e n tr e in g a r o u n d th e p o o r b u re a u c ra ts w h o s e jo b it is t o a d d u p a m a s s o f figures, d iv id e , a n d p r e s e n t th e re s u lts to th e ir chiefs. T h e s e p o o r d e v ils h a v e p r o b a b ly n e v e r seen the n e w m a te ria ls o r c o m p o n e n ts t o w h ic h th e q u e s tio n n a ire re la te . T h u s th e n o tio n a ro s e , w h y n o t e x a m in e a n d d is c u s s o u r o w n q u e s tio n n a ir e s ? Such a s y s te m h a s b e e n o r g a n is e d to c o v e r a lim ited field— th e m a in te n a n c e o f c e r ta in ty p e s o f fo u n d ry p la n t. S e t q u e s tio n s o n th is s u b je c t p r o du ce a n s w e rs o f b u t lim ite d v a lu e , b u t th e y a r e in d ic a tiv e a n d o f d is tin c t w o r t h a s a b a sis f o r f u r th e r d is c u s s io n — n o t m e re ly a c a d e m ic a n a ly se s. A q u e s tio n n a ire w a s s e n t to th e m e m b e rs a s k in g f o r in f o r m a tio n a s to th e m a in te n a n c e o f d iesels, jo lte rs, s h a k e o u ts a n d s a n d r e c la m a tio n sy ste m s.
T h e d iffe re n c e b e tw e e n th e o fficial a n a ly s is a n d th e s u b s e q u e n t d is c u s s io n is m o s t m a r k e d , th e r e p o r t o f the l a tte r b e in g m u c h m o r e u s e fu l. So f a r a s d iesel en g in es a r e c o n c e r n e d , it w a s b r o u g h t o u t t h a t th o u g h m a in te n a n c e c o s ts m a y b e h ig h e r , th e r u n n in g c o s ts w ill ta k e c a r e o f th is a s o n e c a n m a n a g e w ith o n e o p e r a to r a s a g a in s t tw o f o r s te a m lo c o m o tiv e s, a n d tim e is s a v e d th r o u g h th e e lim in a tio n o f th e in itia l lig h tin g u p p ro c e s s . F o r d iesel s h u n t
ing e n g in e s th e r e w a s a g e n e ra l p r e fe r e n c e f o r th e 6 5 -to n o v e r th e 5 0 -to n m o d e l.
W h e n d isc u s s in g jo lte r s , r e fe r e n c e w a s m a d e to th e d e tr im e n ta l e ffe c t th e y h a v e o n s u r r o u n d in g e q u ip m e n t a n d p ro p e rty '. S o m e h a d m o u n te d th e m o n p iles, p r e s u m a b ly w ith g o o d effect. G e n e r a l c o m m e n d a tio n w a s g iv e n t o th e u se o f F a b r e e k a , a p r o p r ie to r y m a te r ia l c o m p o u n d e d o f c o r d e d r u b b e r. T h is is u s e d a s a c u s h io n , a n d is in s ta lle d b e tw ee n th e m a c h in e a n d th e fo u n d a tio n s . M o r e o v e r, it is a lso u s e d a s b u s h in g s a r o u n d th e f o u n d a tio n b o lts , a n d in c o n n e c tio n w ith o t h e r f o u n d r y p la n t s u c h as s h a k e o u ts a n d th e lik e . T h e m a n u f a c tu r e r s o f a p o p u la r A m e r ic a n m a k e o f
s h a k e o u t m u s t h a v e v ie w e d th e r e p o r t o f th is d is c u s s io n w ith m ix e d fe e lin g s as e v e r y b o d y w a s sa tis fie d w ith th e te c h n ic a l re s u lts b u t w e re se v e re ly
c r itic a l o f th e b rig h tn e s s o f th e d e sig n a n d th e h e a v y m a in te n a n c e c o sts. W e th in k th e m a k e r s o u g h t t o b e p le a s e d a s th e y c o u ld n o w m a r k e t a 1945 m o d e l ta k in g ste p s t o e r a d ic a te th e w e ak n e ss es d isc lo s e d . T h e e lim in a tio n o f d u s t a r o u n d s h a k e o u ts is o b v io u s ly s till a s m u c h a p r o b le m in th e U n ite d S ta te s as h e re . T h e fre e in g o f c o re s f r o m c a s tin g s w a s a ls o d is c u s s e d , a n d f a v o u ra b le c o m m e n t w a s a c c o r d e d to th e s y s te m o f s u s p e n d in g th e c a s tin g f r o m th e c r a n e a n d a tta c h in g to it a p n e u m a tic v ib r a tio n . T h e s y s te m h a s n o ill effect o n th e c ra n e . V e r y la r g e c a s tin g s a r e d e a lt w ith b y o n e firm b y m o u n tin g th e m o n sp rin g s o n a w a g o n a n d s trik in g th e ris e rs w ith a p ile d riv e r.
T h e la s t q u e s tio n t o b e d isc u sse d w a s th e r e c la m a tio n o f s a n d b y th e H y d r o - b la s t sy s te m a n d b y a d ry sy s te m . T h e l a tte r c o n s is ts o f p a s s in g th e s a n d th r o u g h v ib r a tin g s c re e n s a n d th e n c a s c a d in g o v e r lo u v re s t h r o u g h w h ic h r e g u la te d a m o u n ts o f a ir a r e d r a w n to r e m o v e th e silt. T h e r e c la im e d m a te ria l is still b la c k , a n d is n o t a s g o o d a s n e w s a n d . T h e sy s te m b e in g n e w , n o r e lia b le c o s ts a r e so f a r a v a ila b le . T h e r e is ju s t o n e f a c to r w h ic h w o rrie s us a b o u t th is d is c u s s io n , a n d t h a t is t h a t it w a s h e ld u n d e r th e aegis o f T a n d O g r o u p . D iv is io n 7. T o o u r m in d , to b e th o r o u g h ly effe c tiv e , every7 p e r s o n w h o h a s h a d th e f a g o f fillin g u p th e q u e s tio n n a ir e s h o u ld h a v e th e rig h t to p a r tic ip a te in th e d isc u s s io n . W e w ell re m e m b e r h e a r in g o f a c o m m itte e d is c u s s io n o n a n en q u iry7 s e n t o u t a s to th e a m o u n t o f p a tc h in g u s e d in c u p o la p ra c tic e p e r to n o f t h r o u g h p u t. W e a r e r e a s o n a b ly s u r e t h a t i f th e m o s t e x tr a v a g a n t a n d e c o n o m ic a l o f th e re p o rtin g firm s h a d b e e n p re s e n t b o th m ig h t h a v e m o d ifie d th e ir p ra c tic e , a s e x cessiv e e c o n o m y in o n e d ir e c tio n o f te n le a d s to e x tr a v a g a n c e in a n o th e r .
Contents
A Q u estio n n aire on M ain ten an ce. 285.—Scientific T each in g a n d B esearch , 286.—Iro n fo n n d ry F n el News—XV, 286.—N otes from th e B ran ch es, 286.—New I.B .F . Section in N a ta l. 286.—
Steel M ixes a n d In o c u la n ts in G rey C ast Iro n , 287.—In d u s t r i a l TTses of L ith iu m a n d its Com pounds. 292.—An O u tlin e of G ra v ity D ie-C asting, 295.—New C atalogues, 297.—S afety F ir s t in C upola P ra c tic e , 298.—New P a te n ts , 299.—New T rade M arks. 299.—B .C J.R .A . E lects New M embers. 299.—P erso n al, 300.—N ews - i n B rief. 300.—C om pany R esu lts, 502.—O b itu a ry , 302—Surplus T in p la te C ap acity . 302.—F u tu re of G overnm ent P la n t. 302.—R aw M a te ria l M ark ets, 304.
S C I E N T I F I C T E A C H I N G A N D R E S E A R C H
S C H E M E A N N O U N C E D B Y I.C.I.
T h e d irecto rs o f Im p e ria l C h em ical In d u stries, L im ited, h av e offered to p rovide a t n ine u n iv ersities in G re a t B ritain F ellow ships to be h eld by sen io r w orkers in certain sciences. T h e schem e is a n n o u n ced to o p e rate f o r an in itial .period o f seven years. T h e F ellow ships w ill b e o f the av erag e value of £600 per a n n u m , th o u g h the universities w ill hav e p o w er to determ in e th e em o lu m en ts fo r e ach p a rtic u la r a p p o in t
m ent. T h e d irec to rs o f I.C .I. hav e d escribed on b ro a d lines th e su b jects in w hich the F ellow ships a re to be h eld, and the ad m in istratio n o f the schem e resits w holly w ith the universities, w hich w ill select an d a p p o in t the F ellow s, su b ject only to such c o n d itio n s as to duties and ten u re as the u n iversities them selves im pose.
T h e p u rp o se o f the directo rs in in stitu tin g this schem e is to stren g th en the g en eral p ro v isio n in the B ritish u n iversities fo r scientific tea ch in g an d research.
T h e d irecto rs believe th a t a ca d em ic a n d in d u stria l r e search a re in te rd e p e n d e n t a n d c o m p lem en tary , an d th a t su b sta n tia l advances in in d u stry can n o t be lo o k ed fo r w ith o u t c o rre sp o n d in g ad v an ces in academ ic science. In th e ir view , it is im p o rta n t th a t the im m e d iate objective sh o u ld be the stre n g th e n in g o f u n iv er
sity scientific d e p artm e n ts in w h atev er w ay each u n iv er
sity th in k s to be best. N o c o n d itio n s w h atev e r are a tta ch e d by the d irec to rs to the ten u re of these F e llo w ships. T h e F ello w s w ill be m em b ers o f th e univ ersity staffs a n d wall be c o n cern ed o nly w ith the d u ties laid u p o n th em by the universities. Tiheir p rim a ry w ork will lie in research . B ut th ey m u st also take som e p a rt in univ ersity teaching. It is in te n d ed n o t to r e lieve the universities fro m the cost o f m ain tain in g any p a rt of th eir n o rm a l w ork, b u t to e n ab le them to ad d to w h a t th e y a lre ad y do .
T h e universities to w h ich th is offer h a s been m ade co m p rise th e larg er m etro p o lita n u n iv ersities a n d those w hich have a close g eo g rap h ical re la tio n to the m ain centres o f the c o m p a n y ’s p ro d u c tio n . T w elve F e llo w sh ip s h av e b een offered to the universities o f O xford.
C am b rid g e an d L o n d o n , eig h t to the u n iversities o f G lasgow , E d in b u rg h , M a n ch ester, B irm in g h am an d L iv erp o o l, an d fo u r to the univ ersity o f D u rh a m . T he d irecto rs believe th a t a ra tio n a l policy o f this c h a ra c ter, to g eth er w ith a wise selection o f m en b o th as reg ard s c ap ab ilities an d te n u re o f office, will lead to th e em ergence o f a bo d y o f m en c ap a b le o f taking high academ ic o r in d u stria l positions, th ereb y a d v a n c ing academ ic an d in d u stria l research.
The American War Production Board is perm ittin g th e m a n u fa c tu re of 68,000 electric cookers fo r civilian use this year.
A W ashington official has stated th a t, in o rd e r to keep the A m erican fo u n d ry in d u stry p ro p e rly supplied w ith te c h n ica l skill, the a n n u al in tak e o f ap p ren tice s m ust be o f the o rd e r of 100,000 a y ear.
I R O N F O U N D R Y F U E L N E W S — X V
F lu e arra n g e m e n ts in drying stoves in th e iro n fo u n d - i-ng in d u stry c ertain ly ran g e fro m the sublim e to the rid icu lo u s. T w o ex am p les o f the la tte r v a rie ty are illu stra te d by th e fo llo w in g e x tra c ts fro m re p o rts by visiting m em b ers o f the R eg io n al P a n e ls o f th e Iro n - fo u n d in g In d u stry F u e l C o m m ittee : “ M o u ld s are dried in a p rim itiv e b rick c h a m b e r . . . th e m o u ld s an d a fire-basket a re b o th s h u t up to g eth e r inside the c h am ber . . . th e flue o u tle t has a d am p er, access to w hich is fro m inside the stove! ” “ T h e stove is h e ated by a fire-basket a t one end. T h e o u tle t flue is im m ediately o ver th is fire-basket! ”F o rtu n a te ly , these ex am p les a re n o t ty p ical; but n evertheless n u m b ers o f cases hav e been m e t in w hich the flue arran g em en ts hav e been f a r fro m satisfactory an d w here relativ ely slig h t a lte ra tio n s c o u ld re n d er the stoves m o re efficient a n d th e re fo re less w astefu l of fuel. T h e p u rp o se o f flues is, o f c o u rse, to convey the h o t gases to, and aw ay fro m , th e stove, a n d their a rra n g e m e n t sh o u ld th e re fo re be such th a t th ere is the m axim um c irc u la tio n o f the gases th ro u g h th e stove so th a t all the lo a d c a n a b so rb som e o f th eir heat.
T h e gases b eco m e co o led a n d lad e n w ith m o is tu re on th eir passage th ro u g h th e lo ad , an d th e re fo re becom e h eav ier th an the fresh h o t gases. T h e o u tle t flue sh o u ld th ere fo re b e ta k e n fro m tihe b o tto m o f the stove, a t the f a r en d fro m th e firebox, an d n o t from the to p , as is o fte n fo u n d to be the case. N eedless to say, an ex h au st d a m p e r sh o u ld be fitted, and used.
N O T E S F R O M T H E B R A N C H E S
S o u th A fr ic a .— T w o visito rs from ' C ap eto w n , M r.G . F. A lex an d er and Mir. N . W atts, o p en ed a discus
sion a t th e A p ril m eetin g o f th e B ra n ch o n “ Is M ass P ro d u c tio n P o ssib le in S o u th A frica ? ” M r. A le x an der to o k th e op tim istic view a n d M r. W atts the pessi
m istic attitu d e . B oth p re sen te d go o d a rg u m e n ts, b ut u n til th ere is a b e tte r d e fin itio n o f m ass p ro d u c tio n th e su b je ct w ill re m a in n eb u ln s. M r. Issels, o f B u la
w ayo, S o u th e rn R h o d e sia, w as p re sen t an d d etailed the n o t in co n sid e rab le p rogress m ad e by the local fo u n d ers in re ce n t years. O n M ay 18, som e 60 m em bers o f the B ranch visited the w o rk s o f the D u n sw art Iro n & Steel W o rk s, L im ited .
N E W I.B.F. S E C T I O N IN N A T A L
A t a w ell-atten d ed m eeting, h eld o n M a y 2, a t D u r b an , a N a ta l Section o f the S o u th A frica n B ra n ch o f the In stitu te o f B ritish F o u n d ry m e n w as in au g u ra te d . M r. T . H . C. O ra m , w ho h a s b e e n a m e m b e r o f the L o n d o n B ran ch fo r the la s t 14 years, w as elected ch airm a n . H e prom ised to ad d ress th e new se ctio n fro m the c h a ir o n the o ccasio n o f the first re g u la r m o n th ly m eeting.A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L 287
STEEL M IXES A N D IN O C U L A N T S G REY CAST IR O N *
By W . B A R N E S and C . W . H I C K S
IN
A ssum ption that melting o f steel in cupolas is a difficult practice is entirely false
M u ch has been w ritten a b o u t the in o cu la n ts an d alloy ad d itio n s in m o d ern h ig h-duty cast iron, and very little a b o u t effects o f th e vario u s am o u n ts of steel in the m ix, b u t th ere is no d o u b t th a t the steel content o f th e ch arg e is the g reatest basic fa cto r in the resu lts o b tain ed . T h ere h as been, and, fo r th a t m atter, still is, too m u c h m isco n cep tio n an d d o u b t about the cu p o la m elting o f steel, and, because o f this, m any fo u n d ries are o p eratin g u n d e r high m etal costs.
As p ro d u ctio n con d itio n s are the acid test of any process, th e follow ing describes a series o f experim ents carried o u t on a cu p o la w hich is in daily use fo r n orm al p ro d u ctio n . E v ery care w as tak en to ensure that m elting con d itio n s fo r these experim ents w ere as consistent as possible, and the m etal charges involved were p laced in the sam e charge sequence in every case. C o n tro l w as established by m eans o f a stan d ard wedge b a r, an d only m eta l w h ich gave th e d ep th of chill estab lish ed as a sta n d a rd w as used fo r the cast
ing o f test pieces; in o th er w ords, any sequence of charges w hich varied fro m the sta n d ard s, how ever slightly, w ere discarded a n d w ere re p ea te d the fo llo w ing day.
T he ch ief p u rp o se o f the investig atio n was to m easure the effect o n physical pro p erties o f increasing percentages of steel w ith an d w ith o u t a m easured am ount o f v ario u s ino cu lan ts. T h e second p u rp o se was to m easu re th e effect o f a fixed percentage of steel an d varying am o u n ts o f in oculants. T h e th ird purpose w as to ascertain th e effect o f increasing p e r
centages o f steel on the re -a ctio n o f the re su lta n t iron to low tem p eratu re treatm en t, an d to oil quenching.
T he follow ing m ateria ls w ere used as ino cu lan ts:—
(1) C alcium silicide; (2) ferro-silicon; (3) alum inium ; (4) a m ixture o f alu m in iu m an d ferro-silicon, an d (5) nickel shot.
B ecause enough has n o t been w ritten a b o u t the m e lt
ing o f steel in the cu p o la , m a n y fo u n d ers a re relu c ta n t to develop it, on the en tirely false assu m p tio n th a t it is very difficult practice. A s a result, they com prom ise by p u rchasing refined irons, a n d as the price o f these iro n s is co n sid erab ly h ig h er th an sta n d ard pig- iron, there is a m ark e d increase in th e cost o f m etal at the spout, w hereas the pu rch ase o f steel scrap and its direct in clusion in th e ch arg e w ou ld n o t only show the sam e im pro v em en t in physical prop erties, b ut the spout cost o f the m eta l w ould be co n sid erab ly reduced.
F o r exam ple, in the fo u n d ry w ith w hich the A u th o rs are connected, a m etal m ix tu re fo r certain castings
• Paper read a t the F o rty -first Annual Meeting of the In s titu te of B ritish Foundryraen. The authors are, respectively Foundry M anager and M etallurgist, Hum ber, Limited.
co n tain in g 65 p e r cent, refined iro n a n d 1 per cent, nickel a d d itio n gave a tensile strength of 13 to 14 tons, w ith a B rinell hard n ess o f 217. T his m ix was replaced by one containing 20 per cent, steel, w ith a sta n d ard pig-iron a n d no nickel, w ith w hich a tensile stren g th o f 15 tons was obtain ed a t the sam e B rinell hardness, w hile the cost o f the m ix w as reduced by 60s. per ton. A n o th e r im p o rta n t p o in t in these tim es of fu el co n serv atio n is th a t the direct use of steel elim inates the fuel req u ired to convert it to refined iron.
I n som e fo u n d ries sm all additions o f nickel are ad d ed as a cu re fo r alm o st every m etal tro u b le, and v ario u s form s o f nickel o r n ickel-copper additions are m ark e ted as m etal im provers o r regenerators.
W hen such alloys are added in reaso n ab le am ounts to p roduce such iro n s as the m artensitic o r austenitic grades their use is justified, b u t the add itio n o f 0.5 to 1.0 p er cent, is n e ith er necessary n o r justifiable, an d ap p ears to serve no purpose (other th an to increase th e m etal cost per ton) th a t c an n o t be achieved by so u n d m elting technique, an d the co rrect selection of ra w m aterials. Such practices m ay m ake a good iron slightly better, b u t they do n o t m ake a bad iron good.
M elting Practice
T h e c u p o la used w as one em ployed on the daily m elting o f iro n fo r n o rm al pro d u ctio n , w ith the follow ing dim ensions:
Shell d ia m e te r.. . . . . . . 60 in.
In tern al diam eter . . . . . . 30 in.
Bed p late to bottom tu y ere s. . . . 28 in.
Bed plate to top tuyeres .. 33 in.
W indbelt . . . . . . 48 in. x 10 in.
B last m ain . . . . . . . . 14 in. dia.
Tuyeres (1st row), 7 a t . . . . 3 in. dia.
Tuyeres (2nd row), 7 a t . . . . 2 in. dia.
T otal tuyere area . . . . . . 71 sq. in.
Standard Preparation.— T h e slag is chipped off p ro p erly to ensure a good fo u n d atio n fo r patching an d a th in clay w ash is applied. T he patching ganister is m illed an d allow ed to tem per overnight, a n d is u sed as dry as possible, w ith only sufficient m oisture to m ak e it adhere. W here deeper pockets are encountered, bricks a re em bedded to m ake the patching firm , an d prev en t cracking. T h e lining is fo rm ed to follow a slight n a tu ra l b u rn -o u t, giving a diam eter of 32 in. ju st above the tuyeres, fo r w hich a gauge stick
is used. .
A ll o b stru ctio n s a re rem oved fro m w m dbelt and tuyeres, the b o tto m doors closed an d p ropped, an d the sand b o tto m is th en ram m ed in. T h e sand is a n o rm al
Steel M ix e s and Inoculants
green m o ulding sand, an d is ra m m ed firm ly to slope fro m th e b ack an d sides dow n to the tap h o le . T he sp o u t is lin ed to flow sm o o th ly dow n fro m the tap h o le to p rev en t undue tu rb u le n ce of the m etal, an d all p atching is then dried th o ro u g h ly .
Preparing the B ed .— T h e ta p h o le is p ro tec te d by selected pieces o f coke, th en flat pieces of w o o d (not too thick) are placed over the sand b o tto m to p ro tect it, a n d the rest o f the w o o d to be used is b u ilt in an inv erted cone, w ith th e free ends restin g ag ain st the tuyeres. T h e cen tre o f the cone is th en filled w ith coke, averaging 5 to 7 in., fro m w hich all green ends
Ta b l e I .— Composition of Raw Materials.
M etal grade. Si S . P Mn
P er cent. Per cent. P e r cent. P er cent.
Steel 0 .2 0 0.05 0.0 5 0.6 0
Pig-iron No. 1 3 .10 0.0 4 0.36 1 . 1
Pig-iron No. 2 4 .50 0 .06 0.37 1.5
Pig-iron No. 3 0 .18 0.014 0.032 0 .35
C.I. scrap No. 1 1.70 0.06 0.25 0.80
C.I. serap No. 2 2 .50 0.09 0.35 0.75
C.I. scrap No. 3 2 .0 0 0.07 0.3 0 0 .70
Ferro-silicon 14.4 — '--- -1-~
are discarded, and ju st less th a n o n e -h alf o f the bed coke is p u t on. T h is is allow ed to b u rn w ith a n a tu ra l d ra ft th ro u g h th e b reast opening, u n til a b rig h t red a t th e lining. T h e sam e a m o u n t o f coke is th en added, and w hen this is b u rn t to a dull red, the bed is poked th o ro u g h ly up an d dow n th ro u g h the tuyeres, and dow n fro m the charging d o o r to ensure th a t any cavities le ft by the b u rn t w o o d are rem oved, so th a t the bed is firm an d c an n o t collapse u n d e r the cupola b urden. T h e h eig h t is th en m ade u p to the established d e p th except fo r the last 8 in., w hich a re p u t o n just b efo re charging, w hen the bed h eig h t is fixed at 42 in.
above the to p tuyeres.
R a w M a teria ls a n d M e th o d o f Charging.
T h e m ax im u m length o f m aterials is 10 in., w idth 8 in.; this reduces the risk o f scaffolding to a m inim um .
C harging sequence is co n tro lled as f o llo w s :— Pig- iro n , iro n scrap, a n d steel scrap. T h e pig-iron and h eav ier scrap is ch arg ed to the outside, an d the lighter m aterials to the cen tre to bring a b o u t as even m elting con d itio n s as possible, because o f the greater d e p th of incandescence a t the lining caused by blast deflection.
W hen ferro -allo y s are charged these are p u t in the cen tre p rio r to th e steel scrap being charged.
Fi g s. 2-5.—Ad d i t i o n s o f Fe r r o- Si l i c o n. 60 o z s.
Pe r To n. To p Le f t; 0% St e e l; n o a d d i t i o n. To p Ri g h t; 70% St e e l; n o a d d i t i o n. Bo t t o m Le f t: 0 % St e e l; w i t h a d d i t i o n. Bo t t o m Ri g h t: 70% St e e l; w i t h a d d i t i o n.
F ive cwt. m etal charges are used, a n d 12^ to 15 per cent, coke, acco rd in g to the p e rcen tag e o f steel, 3 to 4 per cent, o f lim estone being ch arg ed on th e co k e, b ut confined to the cen tre zo n es to m inim ise sco u rin g o f the lining. T h e cu p o la is ch arg ed to th e level o f the c h a rg ing d o o r, b u t n o t ab o v e it, an d h o ld s eleven charges, this level being m ain tain ed u n til th e last ch arg e is p u t on. T h e c o m p o sitio n s o f the raw m ate ria ls, a n d o f the charges used, are show n in T ab les I a n d II.
C u p o la O p era tio n .— A ir is su p p lied a t the ra te o f 1,700-cub. ft. a m inute a t a p re ssu re o f 14 in. W .G ..
a n d the m etal is tap p e d to the clock, an d n o t left to the o p e rato r's discretion. T u y ere s are kep t u n d e r c o n s ta n t su rv eillan ce to ensure th a t h eav y “ slag c u rta in s ”
5 0 4 0 5 0 0 0 . 70
Fi g. 1.— In f l u e n c e o f Fe r r o- Si l ic o n a s a n In o c u l a n t.
ADDITION S OF - 6 0 ? F E R R O -S IL IC O N M T O Z S P E R TON W ITH O U T ADDITION --- WITH ADDITION ---
A U G U S T 10, 1944 F O U N D R Y T R A D E J O U R N A L 289
Ta b l e I I .-— Metal M ixtures Used.
(Percentages of raw m aterials.) M etal grade. 0/o/ °//o 0/
/o % % °//o °//o %
Steel. 0 10 20 30 40 50 60 70
Pig-iron No. 1 30 30 40 30 — — — 10
Pig-iron No. 2 — — — 10 20 35 20 10
Pig-iron No. 3 35 25 — — — — — —
C.I. scrap No. 1 .. 35 35 40 30 — — — —
C.I. scrap No. 2 .. — — — — 30 15 15 —
C.I. scrap No. 3 .. — — — — 10 — ’ — —
Ferro-silicon 5 10
n
12
o 10 20 30 40 50 60 70
STEEL CONTENT
Fi g. 6 .— In f l u e n c e o f Ca l c iu m Si l i c i d e o n St e e l Mix Ir o n s.
are n o t allow ed to fo rm an d in terfere w ith blast d istri
bution, and only in ex ceptional circum stances (such as unexpected breakdow ns) is the b last supply interfered with. W hen the last charges are m elting the volum e of b last is reduced to p rev en t ero sio n o f the lining. A control board, show ing the sequence and tim e o f each tap, is m ade up befo re tap p in g com m ences, in o rd e r to prevent any m isunderstanding in the fo u n d ry , w hich m ight cause a h o ld -u p in m elting.
Pointers in G o o d C upola Practice.
(1). M ake sure th a t the bed is firm and evenly burned.
(2). E stablish a bed height th a t gives h o t m etal at the first tap.
(3). W hen m elting starts the first d ro p s o f iron should be seen to pass the tuyeres n o t so o n er th an tw o m inutes n o r longer th an five m inutes. Should the m etal ap p ear too soon it indicates a low bed, and sh o u ld it ap p ear late the bed is eith er too h ig h o r has n o t been sufficiently b u rn t b e fo re charging.
(4). K eeping the cupola fully charged gives c o n sistency of blast d istribution, an d u n ifo rm p re
heating.
(5). K e ep the tuyeres as clean an d free fro m slag as possible.
(6). U se w ell-graded coke fo r the bed, free from
“ fines.”
(7). In ferio r coke m ay show a p ap er saving in cost, b ut the in ferio r m etal w hich often results is a luxury w hich few foundries can afford.
(8). C harging should be u n d er close supervision, an d p ro p e r d istrib u tio n insisted upon.
(9). O bservations should be m ade of the flame above the b urden a t the charging door. A ro arin g flam e, w ith pale blue cones b urning th ro u g h the top o f the charge m eans excessive air. T he ideal flame is blue-pink, burning spasm odically som e inches above the charge, clinging to the brickw ork, and
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Fi g s. 7 -1 0 .— Ad d i t i o n s o f Ca l c iu m Si l i c i d e. 6 0 o z s . Pe r To n. Fi g. 7 , To p Le f t: 0 % St e e l; n o a d d i t i o n. Fi g. 8, To p Ri g h t: 7 0 % St e e l; n o a d d i t i o n. Fi g. 9 . Bo t t o m Le f t: 0 % St e e l; w i t h a d d i t i o n. Fi g. 10, Bo t t o m Ri g h t: 7 0 % St e e l; w i t h a d d i t i o n.
only occasionally ru nning dow n to th e charge fo r a sh o rt period.
Cupola Design
T h e cu p o la used fo r th e tests in this P a p e r h a d a stack heig h t w hich held eleven 5-cwt. charges, a n d as the m elting rate w as 3-tons an h o u r, this m ean t alm ost an h o u r’s m etal, th u s ensuring a satisfactory pre-heat, b u t the A u th o rs w ish to em phasise th a t any norm al cu p o la will m elt steel mixes. A cu p o la w hich will not m elt steel will n o t m elt any m ixture satisfactorily, even if it be com posed en tirely of pig irons. A satisfactory iron a t the sp o u t is one w hich is clean and h ot, and no
Steel M ix e s and Inoculants
m etal p ro p e rly m elted sh o u ld ta p at less th a n 1,400 deg.
C.
T h e A u th o r’s believe th a t th ere a re o p tim u m ratio s o f tu y ere a re a to cu p o la cross-section, stack h e ig h t to cross-section, w in d b elt to tu y ere area, an d b last m ain to w indbelt, a n d the em p lo y m en t of these ratio s w herever possible reduces an y v ariab le fa cto rs to a m inim um , b u t v ariatio n s in these ratio s b e a r n o co m pariso n w ith the b a d influence o f slipshod cu p o la p ra c tice. W ith so u n d c o n tro l a n d supervision, g o o d m etal can be obtain ed , a n d n e ith e r the a d d itio n o f in o cu la n ts, sm all am o u n ts o f alloy, o r a h igh p ercentage o f refined irons will p ro d u ce a go o d iro n u n d e r b a d practice.
T h e use o f refined iro n s is a m o st expensive m eth o d of attem p tin g to neu tralise a deficiency o f m elting co n tro l, p a rticu la rly w h en it is realised th a t such iro n s are sim ply steel m ixes m elted dow n in som e o th e r cu p o la,
Fi g. 11.- - In f l u e n c e o f 1 % Ni c k e l o n Te n s i l e St r e n g t h.
co n sid erab ly less th a n the p re -h e a t av ailab le on the o th e r cu p o la. T h e re co m m e n d e d r a tio o f tu y ere a rea to a 30-in. dia. cu p o la cro ss-sectio n is in th e vicinity o f 1:5. T h is p a rtic u la r c u p o la h a d a ra tio o f 1:3.7, w hile the first c u p o la h a d a ra tio o f 1:1 0.
T h e c o n tra st betw een the tw o fu rn ac e s w as m o st m ark ed , y et no difficulty w as e n co u n te re d in m elting m ix tu res c o n ta in in g u p to 85 p e r cent, o f steel in this seco n d u n it, a n d m elting ra te a n d tap p in g tem p e ra ture w ere b o th satisfacto ry . A ctu ally , th is fu rn ac e was u sed f o r a p e rio d o f m an y m o n th s o n th e daily m eltin g of 60 p er cent, steel m ixtures.
A b o u t five y ears ago, o n e o f th e A u th o rs m elted 75 p e r cent, steel satisfacto rily in a s ta n d a rd d w a rf cu p o la w ith a m eltin g ra te o f 1 to n a n h o u r. T h is cu p o la
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qu ite p ro b a b ly n o different in design fro m the one into w hich the refined iron is finally charged.
T h e sta te m en t th a t an y n o rm al c u p o la w ill m elt steel has been su b stan tiated in practice by the A u th o rs. In the fo u n d ry w here this research w as carried o u t th ere w as a second cu p o la w ith the follow ing d im e n sio n s: -—
Shell d ia m e te r.. . . . . .. 42 in.
In tern a l diam eter . . . . . . 30 in.
Bed plate to bottom tuyeres . . 28 in.
Bed p late to to p tuyeres . . . . 45 in.
W indbelt . . . . . . . . 26 in. x 8 in.
B last m ain . . . . . . . . 8 in. dia.
Tuyeres (1st row), 4 a t . . . . 8 in. X 3 in.
Tuyeres (2nd row), 4 a t . . . . 8 in. x 3 in.
T otal tuyere area .. . . . . 192 sq. in.
It will be seen th a t the in tern al d iam eter w as the sam e a s the first cu p o la, w ith the sam e m elting rate o f 3 tons a n h o u r. T h e stack in this c u p o la held only fo u r 5-cwt. charges, 20-m in. m etal supply, w hich was
Fi g s. 1 2 -1 5 .— Fi g. 12, Ad d i t i o n s o f 1 % Ni c k e l. To p Le f t: 0 % St e e l; n o a d d i t i o n. Fi g. 13, To p Ri g h t: 7 0 % St e e l; n o a d d i t i o n. Fi g. 14, Bo t t o m Le f t; 0 % St e e l; w i t h a d d i t i o n. Fi g. 15, Bo t t o m Ri g h t: 7 0 % St e e l; w i t h a d d i t i o n.
h a d no w in d b elt, a n d only tw o tu y ere s ru n n in g direct fro m th e b las t pipe. A gain, in this in stan ce th e m eta l was c le a n w ith a h ig h ta p p in g te m p e ra tu re . T hese instances m ay a p p e a r to in d icate a n o p p o site view to the op in io n s expressed a t the b eginning o f this c h a p te r, b u t th a t is n o t so. C u p o la design is im p o rta n t, a n d a c o rre c tly designed u n it w ill give the g re atest fu el effi
ciency, even m elting, m in im u m o f ch arg e d ilu tio n , a n d the least o x id atio n , b u t these are fa cto rs w hich affect the m elting o f an y cast iron.
Control o f Test-bars
T o o b tain as co n sisten t a m elting co n d itio n as p o s
sible the m etal charges to be used fo r test w ere placed o n th e cu p o la in th e sam e sequence d u rin g each m elt.
