Foundry Trade Journal : with which is incorporated the iron and steel trades journal, Vol. 72, No. 1461

(ITISH

WITH WHICH IS INCORPORATED T H E IR 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. No. 1461. A U G U S T 17, 1944 rSingU C o p y id. By Peat •<

k. ^ An .i ,■ r j •> I A nnu al S u b s c rip tio n , Horn

R egistered at the G .P .O . as a Newspaper O ffice s: 49, W ellington Street. Strand, London, W .C .* . ; L a n d O v a rsaa s, 21 /• (P re p aid

I0ULDING IACHINE C ° LT0

Used by many leading foundries

D I S T R I B O N D S T E I N

the PROVEN B R IT ISH substitute for Bentonite D ISTR IC T CH EM IC A L COMPANY LTD.

R E F R A C T O R IE S FOR E V E R Y P U RP O SE

JO H N G . ST E IN & C O . L T D . B O N N Y B R ID G E , S C O T L A N D

MLDAYS & ONIONS LTD

B IR M IN G H A M II oniifnrttirvrs of ** ' ' ~

L p l a n t s

e r i t h r a n g e o f s a n d s

C o m b in e a v a r ie ty of s e l e c t e d L O A M S a n d S I L I C A S A M O S of g o a t a n t e e d q u a l i t y , s u i ta b l e fo r e v e ry a p p r o p r i a t e fo u n d r y re q u ir e m e n t* I n a l l iifn d a m e tu a l r e s p e c t s th e y a f c t h e o u ts ta n d i n g s a n d s fo r p re s e n t-d a y p r a c t i c e , a n d a r e t r i e d a n d p ro v e d b y * ™ / e 5u * t ^ tBfK W rite fo r illu stra te d Brochu re and fr e e Sam ples t o : E S t AB LiSH LL ) loU>

J . PAR ISH & CO., E R I T H , KEN T. T e le p h o n e N o . : E R I T H 1056

FO U N D RY TRADE JO U R N A L A U G U S T 17, 1944

SEND FOR IL LU S T RATEO B R O C H U R E

THE FORDATH ENGINEERING C? L'

TELE PHONE

WEST BROMWICH 0549(2lines)

H A M B L E T W O R K S WEST BROMWICH

t e l e g r a m s

M ETALLICA L.We s t Brom w ich

A U G U S T 17, 1944 FO U N D RY TRADE JO U R N A L 3

“ L I N S L A D E ” A U T O M A T IC SA N D RAM M ER.

FO U N D R Y EQ U IPM EN T L IM IT E D

L IN S L A D E W O R K S

L E IG H T O N B U Z Z A R D , BEDS.

T e le p h o n e : L E IG H T O N B U Z Z A R D 2206-7. T e le g ra m s: “ E Q U IP M E N T ” L E IG H T O N B U Z Z A R D .

HIGH-SPEED MOULDING

LIGHT . STRONG RIGID

P A T E N T A P P L IE D FO R

THE " U B S LADE" SATO RAMMER P a t e n t a p p l i e d f o r FOUNDRY EQUiraENT LIMITED, LINSLADE WORKS, LEIGHTON BUZZARD.

The fa c t that goods made o f raw m aterials in short supply owing to war conditions are advertised in th is paper should not be taken as an indication that they are necessarily available for export

FO U N D RY TRADE JO U R N A L A U G U S T 17. 1944

In

my designs it w ill be possi­

ble to work out a casting or forgin g that w ill weigh pounds instead of hundredweights, or ounces instead o f pounds. In this way the light alloys th at have been developed under the stress o f war are destined soon to lighten the machinery of life in every direction— so that industry, transport, ( and, we hope, international relations) w ill benefit.

That is one o f the reasons why we are so proud to be makers oj aluminium alloys f o r every conceiv­

able purpose.

Au g u s t 1 7, 1 ^ 4 4 FO UN DRY TRADE JO U R N A L 5

B r i t i s h M o u l d i n g M a c h i n e C o . L t d .

6 FO U N D RY TRADE JO U R N A L A U G U ST 17, 1944

P R O D U C T IO N

How to increase production is the chief problem in these days. One of the best and easiest ways is to use Sterling Moulding Boxes. Sterling Boxes have all the qualities required.

They are used in all types of foundries. W h y waste tim e making yo u r own boxes when you can buy something b etter ?

Telephone:

B E D F O R D 5 3 3 8 - 9 Telegrams . S T E R F L A S K • B ED FO R D

T

H E R E is no b e tte r Moulding Box made, and th e re is no o ther Moulding Box “ just as good.” Take no chances; let your next lot o f Boxes be “ Ste rlin g s.”

They are : L IG H T ST R O N G R IG ID A C C U R A T E D U R A B L E

A U G U ST 17, 1944 f o u n d r y t r a d e j o u r n a l 7

P

^{cupolas .}

i l t t t i C

„ r e a n d m ould ja rr rollover san d p re p a rin g ^ b k l u i S T r y e r s

R over san d m ix ers d ry in g stoves m ach ines plan ts . . i - n n x r n v m U \ \

s and m ixing m ills sand d isin te g rato rs

rotary san d dryers portable m ou ld d ryers

R oyer san d m ix ers d ry in g stoves m ach in es pian is D K f r N T f S H A M

P N E U L E C L I M I T E D - M a fe k in q R o a d - S m e t h w ic k - N e a r B IR M IN G H A M

, " * » « * * *

s i r p r e s s u r e s y s t e m ° t h e h o t

* y ™ s r e i n t e r e s t e d “ T SUC« s s f “ '- r y m g 0 f c o r e s a n d u e f f i c i e n t

or i l l u s t r a t e d f o l d e r d e I . p , e a s e “ s ir o n t h i s p r L p r W g S tO T «

8 FO U N D RY TRADE JO U R N A L A U G U ST 17 1944

THOMAS £ ISAAC BRADLEY LTD

Modern Foundry Practice re­

quires careful sand control

COLBOND & SILICA FLOUR

give you this.

C O L B O N D — a f in ^ g ra in e d collodial clay — Is the incomparable foundry bonding m a te ria lfo r mould-., Ing sands for all purposes,.. It possesses, high refractoriness- as .well as a unique degree o f plasticity and adhesiveness and gives the Ideal green sand and dry. sand strength. . C O L B O N D Is in big demand in Iron and Steel Foundries all o v tr the country fo r syn thetic moulding sands, core sands, the renovation of spent sand, core washes and' jo in t­

ing pastes. Economical to handle, it saves space, labour, time and money.

S I L I c A F L O U R — acknowledged by Iron and Steel Foundries every­

w here to be w ith o u t equal for core washes and mould dressings.

It Is available In several grades of particle fineness.

■ . ' - r '

^ "3 r■' T ? "--

* •

I--.-

am-> •• “ ‘ -

B E N T L E Y R O A D . - D A R L A S T O N , - S T A F F S .

FOUNDRY ENGINEERS-METALLURGICAL & ABRASIVE SU PPLIES •

Telephone

DARLASTON

lib -T eleg ra m s

BRADLEY

DARLASTON

356

A U G U ST 17. 1944 -IDRY TRADE JO U R N A L 9

FOUNDRY MECHANICAL PLANT

We are d e sig n e rs and m an ufactu rers o f SA N D PR EPA R A TIO N AND C O N T IN U O U S M OULDINGJPLANTS for all Foundries*

the eq u ip m en t c o m p r isin g V ibratory K nockouts, B and and Steel Apron C onveyors, M agnetic Separators, to ta lly enclosed Bucket E levators, Sk ip H o ists, M ills, A erators, P u sh p la te and M ould C onveyors, S to r a g e 'B in s w ith T able F eeders, Steel and Cast Iron S la t C onveyors, O verhead Chain and T ro lley C onveyors and Cupola^Charging E levators and H o ists

.A

MARCO CONVEYOR &. ENGINEERING CO.

LIM ITED

R o w in W o r k s , L eyto n sto n e, O n W a r Office and A ir M inistry Lists

London, E.11 Midland O ffice : M r. G . H . T a y lo r, London

A ssu rance House, 3 S, Benners H ill, Birm ing-

Telep h o n e : L E Y T O N S T O N E 2 2 5 4 —5 ham, 2 . T e le p h o n e : C e n tra l 2 9 I7

T eleg ram s : E N G IM A R C O , L E Y S T O N jE

10 FO U N D R Y TRADE JO U R N A L A U G U ST 17, 1944

I n t e g r a t i n g p h o t o m e t e r M

A D E a n d u s e d in th e B T H

R e s e a r c h L a b o r a t o r i e s th is re m a rk a b le p re c is io n in s tr u m e n t, o p e n in g in tw o h alv e s m e a su rin g 6 ft. in d ia m e te r, is th e larg e st o f its ty p e.

I t e n a b le s a single m e a s u re m e n t to d e te r m in e precisely th e lig h t o u t p u t a n d lu m in o u s efficiency o f a n y e le c tric la m p ; it is ju s t o n e o f m a n y

sc ien tific d e v ic es e m p lo y e d in th e B T H L a b o r a to r ie s in t h e ir u n r e m i t ­ tin g e ffo rt to m a in ta in a n d im p r o v e th e q u a lity o f M azd a L a m p s .

BTH R E S E A R C H A I D S I N D U S T R Y

B T H R e s e a rc h L a b o r a to r ie s h a v e m a d e a n in te n s iv e s tu d y o f b o t h th e p h y s ic a l a n d p s y c h o lo g ic a l a s p e c ts o f lig h tin g in w a r tim e in d u s tr y a n d th e ir k n o w le d g e a n d e x p e rie n c e a re a t th e d is p o s a l o f th e p rin c ip a ls o f in d u s tr ia l u n d e r ta k in g s th r o u g h th e M a z d a L ig h tin g A d v is o ry S erv ice.

LIGHTING ADVISORY SERVICE

T h e B ritish T h o m s o n -H o u s to n C o . L td ., C ro w n H o u s e , A ld w y c h , L o n d o n , W .C .2 . M 4006

A U G U ST 17, 1944 ru u N D R Y TRADE JO U R N A L

a

im n m a l

y K E IT H B L A C K M A N LTD. M ILL MEAD ROAD, L O N D O N , N.I7Sy

T e le p h o n e s: T o ttenh am 4522 (tw e lv e lin e s) T e le g ra m s : " K e ith b la c Phone London.*1

R O T A R Y FURNACES

FIRED BY FU EL O IL

T O W N S GAS

“ P U LV E R IT E ” O R

C R E O S O T E PITCH

M IX T U R E

S T E IN & A T K I N S O N L TD

47, W O L S E Y R O A D ,

E A S T M O L E S E Y , S U R R E Y .

T E L E P H O N E S : T e l e g r a m s :

M O L E S E Y 3111-2 M E T A S T E I N A , P H O N E , L O N D O N

12 FO U N D RY TRADE JO U R N A L A U G U ST 17, 1944

543

c

S p a ce is so lim ited th e s e d a y s that if w e lis te d all our a g e n ts in e v e r y a d v e r tis e m e n t w e w o u ld h ave no ro o m left to d e s c r ib e w h at th e y s u p p ly . So w e a re d e v o tin g a w h o le la y o u t to th e jo b . It may n ot a p p e a r a g a in for a w h ile , s o p le a s e m ak e a note of y o u r n e a r e s t A g e n t N O W b e fo r e y o u fo r g e t.

M id la n d s : R. J. R ic h a r d s o n & So n s, L td ., C o m m e r c ia l S tre e t, B irm in g h a m , 1. (M id la n d 2281.) N .E . C o a s t : J. P a r m le y G ra h a m & Sons, L td ., Sun B u ild in g s, C o lh n g w o o d S tr e e t, N e w c a s tle -o n -T y n e .

(N e w c a s tle 23983.)

S c o tla n d : M itc h e ll G ra h a m & Son, L td ., 56 B u c c le u c h S tre e t, E d in b u r g h . ( E d in b u r g h 42025.) C a n a d a : W illia m s & W ilso n , L td ., 544, I n s p e c to r S tre e t, M o n tre a l ( M a r q u e tte 4591) a n d 137,

W e llin g to n S tr e e t W e s t, T o ro n to .

I n d ia : A. C. B o tto m ley & C o ., S tro n a c h H o u s e , G r a h a m R o a d , B a lla rd E s ta te , B om bay.

(B o m b ay 22333.)

A u s t r a lia : A s s o c ia te d M a c h in e T o o ls (A u s tra lia ) P ty ., L td., 260-262, K en t S tr e e t, S y d n e y (B.7663) a n d 546-566 C o llin s S tre e t, M e lb o u r n e (M. 1551).

N e w Z e a la n d : R ic h a rd s o n , M c C a b e & C o ., L td., 11, G r e y S tre e t, W e llin g to n . (42-076.)

S ou th A fr ic a : V ic to r K en t (T ra n sv a a l) P ty ., L td., 12, S a u e r S tr e e t E xt., S e lb y T o w n s h ip , J o h a n n e s b u r g , 7 (33,3015) a n d 62, O r d n a n c e R o a d , D u rb a n .

SAND BLAST PLANTS, AIR COMPRESSORS, DUST ARRESTERS, ABRASIVES

and AIRLESS WHEELABRATOR ABRASIVE CLEANING EQUIPMENT

(S ole su p p lie r s in British E m p ire e x c lu d in g C anada).

liLG H M A N T

PATENT SAND BLAST CO . LTD.

L ondon O ffice : 17, G r o sv e n o r G a r d e n s, S .W .l (V ic. 2586)

A U G U ST 17, 1944 FO U N D RY t r a d e j o u r n a l 13

IN CR EA SE MOULD PRO­

DUCTION AND R E D U C E F O U N D R Y C O S T S B Y MOULDING E L E C T R IC A L L Y .

B .I. Magnetic Moulding Machines are the only moulding machines in the w orld which utilise elec­

tric ity as the direct medium for high produc­

tion w o rk .

M A G N E T I C M O U L D IN G M A C H I N E S

B r it is h P a te n ts N os. 321777, 471690,500566

provide th e cheapest and m ost rapid m eans

^ of producing v accu ra te m oulds.

B R IT IS H IN SU LA TED C A B LE S L IM IT E D Head Office : P RES C O T, LANCS. Tel. No. Prescot 6571

CREOSOTE-PITCH F IR IN G : a „ u m b e r o f firm s adopting th is fuel have e n co u n tered n e w R e fra c to ry P rob lem s caused by C o rro s io n and V itrific a tio n Sp alling. B u t, if a su ita b le design o f b u rn e r is used , the tro u b le can usually b e o ve rco m e by using a H igh A lu m in a F ir e b r ic k such as N E T T L E —a p o in t p ro ve d by the p ra ctica l e xp e rie n c e o fs e v e ra l cu s to m e rs . A n additio nal p ro te c tio n to th e b r ic k w o r k b y w ashco ating w ith M aksiccar II o r Stein S lllim a n ite C e m e n t w ill often be found e co n o m ic. F u rth e r in fo rm a tio n w ill be gladly sup plied on re q u e st.

S e le c te d high g ra d e ra w m aterial and careful technical control at all stages of manu­

facture from the mine to the loading bank ensure the con­

s is t e n t h ig h q u a l i t y of N E T T L E (42/44% A lum ina) Fire b ric k.

14 FO U N D RY TRADE JO U R N A L A U G U ST 17, 1944

Y o u can h a v e it b o th w a y s !

T h e re is som ething to be said for th e conservative m ethod o f m an u factu rin g pig iron w ith plenty o f lim estone in th e ch arg e— it does keep dow n th e su lp h u r content of th e iron. T h e re is a lot m ore to be said for th e m odern tendency to operate th e blast furnace w ith a leaner burd en and thus increase o u tp u t — m axim um iron production needs no b rief in these days. No, we are no t overlooking th e resulting additional su lp h u r pick-up, b u t you can — if you treat th e iron in th e ladle w ith Sodium

Carbonate. In th e case of m ost grades of cast iron, trea tm e n t in the

f i c i \

ladle w ith 1% dense sodium carbonate rem oves 50% of the sulphur present in th e metal. Sim ple, effective, econom ically increased output.

I M P E R I A L C H E M I C A L I N D U S T R I E S L I M I T E D

A U G U ST 17, 1944 FO UN DRY TRADE JO U R N A L 15

r ^Forget

r y o u r R u st ^ problems

by remembering

R ^{u s k il l a t l a s CT}

IRON & STEEL PRESERVATIVE PAINTS

— the Paints o f Stamina !

C o lo u r C a rd , p articulars and prices fro m

Sole M frs.

ATLAS PRESERVATIVE COMPANY LTD

L U N D E R C L IF F W O R K S , E R 1 T H , K E N T J Telephone : E R IT H 2255-6

P A T E R S O N H U G H E »

E N G IN E E R IN G C O M P A N Y LIM IT E D V Be dfo rd H o use, B edford S t ., Stran d , W .C .2 T em p le B a r 7274/6 W y n d fo rd W o r k s , M a ryh ill, G lasg o w , N .W . M aryhlll 172/3

Established 1902

T R A D E J O U R N A L

WITH w h ic h 7S INCORPORATED T H E IR O N A N D S T E E L T R A D E S ¡O U R N A L

49, W ellin g to n S tre e t, Londo n, W .C .2 .

W A R T IM E A D D R E S S to w hich all com m unications should be sent i — 3 , A m e r ih a m R o a d , H I G H W Y C O M B E , B u ck*.

’ G ram s 1 M Zacatecas, High W yco m b e .”

’ Phone i H IG H W Y C O M B E 1792 (3 lin es).

P U B L IS H E D W E E K L Y i 21s. per annum (H o m e and O v erse a' ) O F F IC IA L O R G A N O F t

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 Chairm an i F ltzH e rb e rt W rig h t, T he B u tte rle y Com pany R ip ley, near D e rb y. Secretary I V . D e lp o rt, 2, C axto n S tre e t, W estm ln sto r.

S .W .I .

Participating Associations l B ritis h Bath M anufacturers' Asso ciatio n B ritish Iro n fo u n de rs’ Association ; B ritish Malleable Tub e Fittings A sso ciatio n ; Cast Iro n A x le b o x Association ; Cast Iron C h a ir Asso cia­

tion ; Cast Iro n H eating, B o ile r and Radiato r M anufacturers’ Association!

C ast Iro n Segment Asso ciatio n ; G reensand Pipe Fo un de rs'A sso ciatio n of S co tlan d ; Iro nfo un de rs' N atio nal C onfederation ; N ational Associa­

tion o f Malleable Ironfounders ; N ational Ingot Mould Association ; N atio nal Ironfoundlng E m p lo y e rs ’ F e d e ra tio n A sso ciatio n o f A u to ­ m ob ile and A llie d H ig h D u ty Ir o n fo u n d e rs ; B ritis h C ast Iron Research Association (a ffilia te d ); B ritish G r it Association' (a ffilia te d );

Flushing C is te rn M akers’ Asso ciatio n (affiliated) ; In stitu te o f B ritis h F o un drym en (a ffilia te d ). _______

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 ID E N T , 1943-44 : D . Sn arp e, F o u n d ry P lan t & M a c h in e ry , L t d . 113 W e s t R eg e n t S t r e e t , G lasgow .

G eneral Secretary i T . Makemson. A c tin g S e c re ta ry , J . Bolcon Saint John Stree t Cham bers, Deansgate, Manchester 3.

B R A N C H E S

Birm ingham , C o ve n try and W e st Midlands I A . A . T im m in s, F .I.C 33 C a r t e r s Lan e , Q u in to n . B ris to l and W e s t of E n g la n d : A . H ares, 2 0 , G re e n b a n k R o ad , H anh am , B ris to l. E. Midlands 1 S . A . H o rto n ” T h re e .” Mostyn A venu e, L ittle o v e r, D e rb y. Lancs : H . B u c k ­ le y , E lle s m e re , N o rfo lk A v e n u e , B u r n le y . London l V . C . Fa u lkn e r, 3, Am ersham Road. High W yco m b e. Middlesbrough (pro 'em .) : J . K . Sm ithson, N o rth -Eastern Iron Refining Com pany, Lim ite d , Stilllngton, Stockton-on-Tees. N ew castle-u p o n -Tyn e: C . Lashly, S ir W . G . A rm ­ strong, W h itw o rth & C o . (Ironfou nders), L td ., Close W o rk s , Gateshead Scottish i J. B e ll, 60, S t. Enoch Square, Glasgow. Sheffield : T . R . W al k e r, M .A ., English S te e l C o rp o ra tio n , L t d ., Sheffield. W ales and Monmouth i A . S. W a ll, 14, P alace A v e n u e . Llan daff, C a rd iff. W est Riding of Y o r k s h ir e : Douglas Je p so n , M .Sc., 9 , Am bleslde A v e n u e , B rad fo rd . South A frica : B . P . S k o k , Mutual Building, Johannesburg.

S E C T IO N S

Bu rn le y I H . Bu ck le y, E llesm ere, N o rfo lk A venue. Bui „ le y , Lancs.

Cape! T o w n : K . Z w a n z l_ e r, P .O . B o x 346, Cape T o w n , S. A fric a . East Anglian l A . N . S u m n e r, 5 1 6 , N o rw ic h R oad, Ipswich Falkirk : T . R . G o o d w in , " V le w fie ld ,” F a lk irk Road, Bonnybrldge. Lincoln : E . R . W a lte r, P h .D ., T h e Technical Co llege, Lin 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 re s id e n t : H . B ls s e ll, J. Stone & C o ., L t d ., Lo n d o n . S e c re ta rie s : H eathcote & C o le m a n , 2 5 , B e n n e tts H ill, Birm in gh am , 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 resident : W . H . W h ittle , W . H . W h ittle , Lim ite d , E cd e s, near M anchester. Chairm an i W . T o d d , P arkin so n S to ve C o ., L t d ., Stech- fo rd , B irm in g h a m . H on. Sec. : W . T h o m as, A .I .C ., B an k H o use, High S t re e t, R lc k m a n s w o rth , H e rts .

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 resident I G . E . France, A ugust’s, L im ite d , T h o rn T re e W o rk s , H alifax. H o n o ra ry S e c re ta ry : K . W . B ridges. A ssistant S e c re ta ry : Miss L . C o x , 52, Surbiton H ill P a rk, Su rb iton, 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 President i W . E . C le m e n t, C .B .E ., Morfa Foun dry, N e w D o ck , Llan elly.

S e cre ta ry 1 J . D . D . D avis, I , S t. James G arde ns, Swansea.

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 lvsch u rch , Birmingham. ’Phone a n d ’G ram s : Reddltch7>6.

Scottish L a b o r a t o r ie s F o u n d r y Technical In s titu t*.M eek’s Road, F a lk irk . (Phone I 332./

T H R E E - M O T O R

W A L L

C R A N E

16 FO U N D RY TRAD E JO U R N A L A U G U ST 17, 1944

T h e n eed fo r all p o s s ib le c o n s e r v a tio n o f m a n p o w e r ; th e d em a n d fo r th e m a x im u m o u t p u t o f v ita l c a st m e ta llic p r o d u c ts ; th e in s is te n c e u p o n th e lo w e s t c o s t o f p r o d u c ­ t io n ; and th e n e c e s s ity o f m a in ta in in g , an d e v e n im p r o v in g , th e q u a lity o f th o s e p r o d u c ts .

A ll th e s e c o n d itio n s c o m b in e t o p o in t t o th e o n ly sa tisfa c to ry s o lu t io n to all th e s e p r o b le m s —

M E C H A N IS A T IO N

b u t it m u s t b e m e c h a n is a tio n p a r tic u la r ly c o n s id e r e d , d e sig n e d and a d a p ted to th e in d iv id u a l s ite c o n d it io n s ; to th e p articu lar p r o d u c t ; and w ith fu ll regard t o

a ll

th e fa cto r s, e c o n o m ic , g eo g ra p h ica l and h u m a n , w h ic h m ay ha v e any b earing o n th e pr<?blem.

In o th e r w o r d s c o n s u lt :—

" The Specialists in F ou n dry M ech an isation ”

w h o s e p r o d u c ts

" S et th e S tandard b y which F ou n dry Plant is ju d g e d .”

LIM ITED

’P h o n e s : 6 1 2 4 7 & 8

H A L IF A X , ENG LAND

’G ram s : A u g u s t, H a l i fa x Sole L icen sees a n d m a n u fa c tu r e r s fo r B r itis h E m p ir e ( e x c lu d in g C a n a d a ) o f th e S im p s o n S a n d M ix e r

Foundry Trade Journal, A ugust 17, 1944

C s t a b /i s h e d / 9 0 2

w it hw h ic h H INCOVOMTED T H E IR O N A N D S T E E L T R A D E S JO U R N A L

Vol. 73 T h u rsd a y, August 17, 1944 N o. 1461

Transom Business

M r. J . H . V a n D e v e n te r , th e E d ito r o f th e “ I r o n A ge,” h a s d r a w n a tte n tio n to th e d a n g e r s o f w h a t he calls “ T r a n s o m B u sin e ss.” T h is p h r a s e is n ew to us, b u t i t le a v e s o n e w ith th e im p r e s s io n th a t it is s o m e th in g e x tra . H o w e v e r, w e a re f a v o u re d w ith a d e fin itio n w h ic h r e a d s “ T r a n s o m b u sin e ss is b u sin e ss y o u h a v e n 't s o ld .” B e c a u se o f c o n ­ trols, th e f o u n d r y in d u s tr y h a s n o t e n c o u n te r e d m u ch o f th is ty p e o f b u s in e s s d u r in g th e w a r p erio d , b u t th e y a r e c o g n is a n t o f its im p lic a tio n s in o th e r lin e s, f o r w h o h a s n o t m e t th e in d iv id u a l who g lib ly a s s e rts t h a t h e is re a lly s p e n d in g v e ry little o f h is o w n m o n e y w h e n ex ce ss p ro fit ta x is ta k e n in to c o n s id e r a tio n ? T h e tim e is ra p id ly a rriv in g w h e n th e f o u n d r y in d u s tr y w ill b e o ffere d m u ch tr a n s o m b u s in e s s , f o r th is is a d ire c t c o n s e ­ q u en ce o f e x ce ssiv e ly h ig h ta x a tio n . I ts a c c e p t­

ance n e e d s c a r e f u l s tu d y .

F o u n d r y o w n e r s s h o u ld c a re fu lly s c ru tin is e all tra n s o m b u s in e s s , e sp e c ia lly w h e re th is n e e d s th e e x p e n d itu re o f la rg e s u m s o f m o n e y o n a sp e c ia lis ed p la n t f o r its e x e c u tio n . W o r th w h ile b u s in e s s is se ld o m th e r e f o r th e a s k in g . I t n e e d s to b e s o u g h t.

W e b e lie v e t h a t a t th e m o m e n t in d u s tr ia l c o n d itio n s are s u c h t h a t p o s t- w a r o r d e rs s h o u ld b e s o u g h t.

It is o b v io u s th e r e is m u c h w o r k to b e d o n e , a n d tim e s p e n t e x a m in in g p r e -w a r o r d e r - b o o k s o b je c ­ tively w ill n o t b e w a s te d . S y s te m a tic in q u ir y m a d e no w a s to w h a t o ld c u s to m e r s i n te n d to d o in th e fu tu re w ill e n a b le a s k e le to n p la n to b e e s ta b ­ lish ed f o r f u tu r e a c tiv itie s . T h u s a r m e d , a c le a r c o n c e p tio n c a n b e g a in e d a s to w h e th e r a n y tra n s o m b u s in e s s s h o u ld b e s e rio u s ly e n te r ta in e d . T ra n s o m b u s in e s s ty p ifie s a s e lle r's m a r k e t, a n d calls f o r th e d is p la y o f th e sa m e d e g re e o f c o m ­ m e rc ia l a c u m e n a s w h e n p re s s u re is a p p lie d bv th e b u y e r in tim e s o f d e p re s s io n . T h e d a n g e r is sp e c ia lly p r o n o u n c e d w h e n it im p in g e s o n th e sm a lle r c o n c e rn s , a s th e y m a y fin d th e m s e lv e s la n d e d w ith “ o n e b ig c u s to m e r .” T h e r e is o n e w ell k n o w n p r o s p e r o u s f o u n d r y w h ic h a t o n e tim e in its c a r e e r f o u n d its e lf o p e r a tin g as a s u b s id ia ry c o n c e r n o f a la rg e f irm in liq u id a tio n . T h a t w a s th e re s u lt o f a c c e p tin g tr a n s o m b u sin e ss.

A f te r th e w a r th e r e w ill b e a lu ll o f s h o r t d u r a ­ tio n b e f o re m a n y o f th e f o u n d r ie s w ill b e in ­ u n d a te d w ith e n q u irie s , a n d th is lu ll is th e c ru c ia l p e r io d , f o r it m u s t b e u tilis e d f o r th e e s ta b lis h m e n t o f a m a n u f a c tu r in g p o lic y o f a m a n a g e a b le a n d p ro g re s s iv e c h a r a c te r. S o m e , s e c tio n s o f th e in d u s tr y w ill n o t b e in th is h a p p y p o s itio n , a n d f r o m th e o u ts e t w ill h a v e to la u n c h a c a m p a ig n to a tt r a c t b u s in e s s to th e fo u n d r ie s w h ic h w o u ld b e c la im e d b y c o m p e tin g in d u s trie s . T h is is e sp e c ia lly th e c a s e w ith th e ste el f o u n d e rs , b e c a u se th e ir a c tiv ity is a v e rita b le b a r o m e te r o f a rm a m e n t p r o d u c tio n . T o r e p la c e m u n itio n s b y o rd e rs fro m th e m e rc a n tile m a r in e , th e ra ilw a y , m in in g a n d e n g in e e rin g in d u s trie s a n d still m a in ta in p ro d u c tio n a b o v e t h a t d a tu m lin e , b e lo w w h ic h lo sses a re c e r ta in , w ill n e e d e v e ry o u n c e o f in itia tiv e th e in d u s tr y c a n m u s te r. T o r e tu r n to a 100,000 to n s p e r a n n u m p r o d u c tio n w ill p la c e th e w h o le in d u s tr y in C a r e y S tre e t. A ta r g e t f o r a t le a s t 300,000 to n s s h o u ld b e set, a n d a c tio n ta k e n to see t h a t it is a c h ie v e d . T h e lig h t a llo y se c tio n a lso w ill h a v e a n u p h ill fig h t to m a in ta in w a r tim e p r o ­ d u c tio n level. H o w e v e r, th e y a re ta c k lin g th e p ro b le m e n e rg e tic a lly a n d , in g e n e ra l, in te llig e n tly . T h e issu e o f b o o k le ts o n su c h s u b je c ts a s h in ts on m a c h in e ry lig h t a llo y s, is e x c e lle n t p r o p a g a n d a , th e n e e d f o r e x p a n s io n in b o th steel a n d lig h t a llo y s b e in g im p e ra tiv e . T r a n s o m b u sin e ss w ill b e w e lc o m e d , a n d a g a in to q u o te M r. V a n D e v e n te r :

“ T r a n s o m s a r e n o t o n e -w a y o p e n in g s , a n d b u s i­

n e s s c a n f lo a t o u t o f th e m a s w e ll a s in th r o u g h th e m .” In itia tiv e , h o w e v e r, w ill p ro v id e a d ju s t­

a b le s h u tte r s f o r e n s u rin g th e r e te n tio n o f su c h b u sin e ss.

Contents

T ransom B usiness, 305.—Core B onding, 306.—lro n fo u n d ry F u e l N ew s—X V I, 306.—Cupola Iro n in O p en -H earth E urnaces, 306.—Sand fo r M agnesium F o u n d ry P rac tic e , 306.—Develop­

m en t of a F lu x D eg assin g Process for C hill-C ast Tin Bronzes, 307.—A M azda F o u n d ry L ig h tin g In s ta lla tio n , 311.-=

G rey Ir o n a t E lev ated T e m p eratu res, 311.—Ten B u ies for th e B rassfo u n d er. 311.—A m erican C eram ic Society, 312—The F u tu r e of P a te n ts , 312.—Steel M ixes a n d In o c u la n ts in G rey Cast Iro n , 313.—P e rso n a l, 320—Steel P rice Schedules, 320 —

\f r i c a n Ore E x p o rts to B rita in , 320.—N a tio n a l C ertificates in M etallu rg y , 320.—N ews in B rief. 322.—C om pany B esu lts, 324 — New- C om panies, 324.—B aw M a te ria l M ark ets, 326.

306 FO U N D RY TRAD E JO U R N A L A U G U ST 17, 1944

C O R E B O N D IN G

In a P a p e r, “ Tlhe B o n d in g P ro p e rtie s o f M ixtures o f P e tro le u m E x tra cts a n d L in seed O il an d o f the E x tracts T h em selv es,” w hich M r. W. D avies, M .Sc., an d D r. W. J. R ees h a v e p re p a re d fo r p re se n ta tio n to the Iro n an d Steel In stitu te th ro u g h the S teel C astings R esearch C o m m itte e (M o u ld in g M a terials S u b -C o m ­ m ittee), the a u th o rs h a v e draw n th e fo llo w in g c o n ­ clusions:—

(1) In sa n d m ixes b o n d e d w ith 2 per cent, o f linseed oil up to 40 p er cent, o f th e o il c a n b e re p la c e d by any o f the p e tro leu m e x tracts ex am in ed , ex cep t G ro u p 1A(140) ex tract, w ith o u t ad v ersely affecting th e te n ­ sile stren g th . I f m o re th a n 50 per cent, o f th e o il is rep laced by e x tra c t, th e te n s ile stre n g th fa lls off sh arp ly . M ixtures c o n ta in in g u p to 40 p e r cent, o f e x tra ct re q u ire the sam e m illing a n d d ry in g c o n d i­

tions as th o se c o n ta in in g linseed oil a lo n e to give the op tim u m tensile stren g th . P rem ix in g o f th e Linseed oil an d e x tra c t b e fo re a d d itio n to the san d tends to give a m o re u n ifo rm mix.

(2) U p to 50 per cent, o f th e linseed oil in co re

c o m p o u n d s rich in starch can be re p la ce d by ex tra c t;

this re p la ce m en t gives a n increase in g reen stre n g th , w ith o u t a lterin g the dry stre n g th ap p rec ia b ly .

(3) U p to 40 p e r cen t, o f th e lin seed oil in core co m p o u n d s rich in d e x trin can be re p la ce d by ex­

tract; th is re p la ce m en t in cre ases th e g reen stren g th , b u t is a c c o m p a n ied by a slight loss in d ry strength.

(4) T h e re p la ce m en t o f 50 per cent, of th e linseed oil in core c o m p o u n d s rich in -molasses gives a n in ­ crease in green stre n g th , b u t red u ces the. dry c o m ­ pressive an d tensile stren g th s; a t the sam e tim e, the su rface friab ility increases slightly.

(5) T h e re p la ce m en t o f 40 to 50 p er cen t, o f the linseed oil in c o re co m p o u n d s rich in su lp h ite lye reduces the dry co m p ressiv e an d tensile strengths.

(6) Sand m ixes b o n d e d w ith 2 o r even 4 per cent, o f e x tra c t give dry ten sile stre n g th s fa r below th a t o f m ixes co n ta in in g 2 per cent, of linseed oil. T est- pieces o f th e e x tra c t m ixes have ex tre m ely fria b le su r­

faces. N e ith e r an in crease in drying tem p e ra tu re fro m 200 to 250 deg. C. n o r the use o f driers a t 200 deg. C.

gives m u ch im p ro v em en t. F ro m this, it a p p e a rs u n ­ likely th a t the ex tra cts co u ld w holly rep lace the lin ­ seed oil in m ixes co n tain in g th is b o n d alone.

(7) T h e re p la ce m en t o f linseed oil by a n ex tra ct/

lin seed -o il m ix tu re co n ta in in g 40 to 50 p er cent, of e x tra c t does n o t a lte r th e strip p in g q u a litie s o f sand m ixes.

“ (81 O f th e e x tracts tested, G ro u p 1(72) gives th e best all-ro u n d resu lts a n d its co n sisten cy is su ch th a t it can b e easily han d led .

(9) T h e ab o v e con clu sio n s are based on w o rk w ith O h e lfo rd sand, b u t tests on. a n u m b er o f m ix tu res w ith A rn o ld ’s 52 (L eighton B uzzard) sand lea d to sim i­

la r conclusions.

S A V E W A S T E P A P E R

IR O N F O U N D R Y F U E L N E W S — X V I

T h e experience o f th e R eg io n al P a n e l m em b ers of the Iro n fo u n d in g In d u stry F u el C o m m itte e show s th at on e o f th e easiest an d m o st p ro fitab le w ays o f saving fu el in m o u ld an d co re-d ry in g stoves w hich a re used fo r b atch w o rking (generally one b a tc h p e r n ight) is to keep th e stove d o o rs c lo sed d u rin g th e d a y tim e as m uch as possible.

It is n o t p e rh ap s realised as m u ch as it m ight be th a t the a m o u n t o f coke re q u ire d to h e a t up the brick­

w ork o f a m ed iu m sized stove fro m a ir tem p eratu re to w o rk in g te m p e ra tu re m ay a m o u n t to som e tw o or th ree h u n d red w eig h ts, o r ev en m o re. If the stove d o o rs are left o p en fro m , say, the first th in g in the m o rn in g u n til th e stoves are lo ad ed in the aftern o o n , m o st o f this h e a t is lost, a n d a c o rre sp o n d in g extra am o u n t o f coke m u st be used d u rin g the follow ing n ig h t to com p en sa te. T h u s m an y to n s o f coke are w asted in a y ear.

It will be a p p a re n t th at the m ax im u m use should th e re fo re be m ad e o f bogies w h ich can be left outside the closed stove an d lo ad ed as c o n v en ien t, and that the o p e n in g o f th e d o o rs to a d m it m en to lo ad work on shelves sh o u ld be m inim ised. N eedless to say, stove d o o rs sh o u ld fit well (pay special attention to the to p s o f vertical sliding d oors), an d should be jam m ed tight, if necessary.

C U P O L A IR O N IN O PEN - H EA R T H F U R N A C E S

O f in te re s t to cu p o la m a n u fa c tu re rs in this country is the fa c t th a t A m erica h as n o w th re e cu p o la pre- m eltin g in stallatio n s to- su p p ly h o t m eta l to open- h e arth fu rn ac es. M r. W illiam C . B uell, jun., who ad d ressed the 27th a n n u a l c o n fere n ce o f the Open- H e arth S teel a n d B last F u rn a c e a n d R a w M aterials C o m m ittees of the A .I.M .E . on th is su b ject, stated he did n o t h o ld o u t m udh h o p e fo r the fu tu re o f the process, as th e co st o f c o n v ersio n in th e cu p o la was too high, being o f the o rd e r o f 10 d o lla rs a ton, a lth o u g h five d o lla rs a to n w as given b y a m em ber d u rin g the discussion. A second P a p e r by M r. H ughe B arnes, c o n su ltin g en g in e er to the A rm co concern, re p o rte d a re d u c tio n in the o p e ra tin g tim e in the open- h e a rth th ro u g h the use o f m o lte n cu p o la m etal.

S A N D FO R M A G N E S IU M F O U N D R Y P R A C T IC E

M r. O scar B lohm , w riting in the “ Iro n A g e,” gives the fo llow ing d a ta in c o n n ec tio n w ith th e m ak e -u p of sand su ita b le fo r m ag n esiu m fo u n d ry p ractice. The A .F.A . g ra in size is to b e o f the o rd e r o f 70 to 80.

Sand (w ashed an d dried silica) ... gqq B entonite ... ... io lb s' A m m o n iu m si lie o flu o rid e 26 lbs"

S u lp h u r 7 jb s '

Boric acid 10 lbs

D iethylene glycol 2 lbs'

W ater ... 5 to 8 qts

DEVELOPM EN T OF A FLU X DEGASSING

PROCESS FOR CHILL-CAST TIN BRONZES* T'ZTcZlfJi

a u g u s t 17. 1944 FO U N D RY TRADE JO U R N A L 307

By W . T. P E L L - W A L P O L E ,

T he req u irem en ts fo r a successful oxidising flux process are sum m arised as follow s:— (1) T he flux m ust carry an easily dissociated oxide, p referab ly an oxide o f one o f the m etal c o n stitu e n ts o f the alloy, so that com plete red u ctio n does not seriously co n tam in a te the b a th ; (2) the flux m ust be a solvent fo r any oxide skins p resen t in the ch arg e o r fo rm ed d uring m elting;

(3) at m elting tem p e ra tu re the flux m ust have a co n ­ sistency such th at it form s a co n tin u o u s layer over the melt, an d can be readily m ixed w ith the latter to facilitate reactio n s a n d d issolution of oxides; (4) a su it­

able th ickening ag en t m u st be selected w hich will mix w ith th e flux to get it a pasty consistency so th at it can be rem o v ed com pletely fro m the m eta l before deoxidation. T he th ick en er m u st n o t co n ta m in a te the melt eith er directly or by reactio n w ith the flux; (5) the necessary q u an tity o f a su itab le d e o x id a n t m ust be added to the m elt to rem ove excess of oxygen. T he products o f th e d eo x id atio n reactions m ust be readily rem ovable fro m the m etal, an d residual deo x id an t m ust not adversely affect the m echanical o r w orking p ro ­ perties o f th e b ro n ze, a n d (6) the flux should be of simple co m p o sitio n , easily p re p are d , cheap, n o t objectionably fum ing, a n d should n ot a ttack the m elt­

ing pot. T h e experim ents described below w ere planned to develop a process w hich w ould m eet these requirem ents.

Selection of Materials for an Alternative O xidising-Flux Process

C u p ric oxide w as chosen as the oxidising agent, since it dissociates a t the tem p e ra tu re o f o p e ratio n and even if com pletely red u ced does n o t co n tam in ate the m elt. T ech n ically pure oxide w as used in prelim in ary experim ents, b u t later co p p er m ill scale was found satisfactory as a su b stitu te. M aterials to a ct as carriers f o r the c o p p er oxide w ere selected fro m those w hich are relatively ch eap a n d are n o t strongly basic in reactio n , viz., fused boric acid an d b o rax , sodium chloride a n d sodium fluoride, all o f com m ercial purity.

S to u rb rid g e sand an d co m m ercial bo n e ash were used fo r th ickening the flux, e ith e r alone o r fritte d w ith o ne-third p a rt by w eight o f b o ra x or sodium fluoride.

All th e m aterials w ere dried th o ro u g h ly a n d sto red in air-tight containers.

Experiments on Fluxing Procedure

B efore investigating the effects of different flux c o m ­ positions, it w as necessary to develop a satisfacto ry fluxing pro ced u re. F o r this p u rp o se a flux co ntaining

* E x t r a c ts f ro m a P a p e r re a d b efore th e I n s tit u te o f M etals. T he a u th o r is C h ief M e ta llu rg ist, T in R e se a rc h I n s tit u te .

B sc., Ph D . oxidising flux process

eq u al p a rts by w eight of copper oxide, boric acid, sodium fluoride, an d sodium ch lo rid e, was used a t the ra te of 1 oz. o f flux per lb. o f m etal. T h is gave a cover i to 1 in. deep w ith m elts of 10 to 30 lbs., an d an av ailab le oxygen c o n te n t m uch greater than th a t req u ired theo retically in the m elt to ensure a m inim um h y d ro g en content.

M elts o f 9 to 14 per cent, tin bronze were prep ared fro m virgin m etals (cathode copper, C h e m p u r tin) or fro m scrap, in salam an d er pots in a gas-fired pit fu rn ace. T h e follow ing facto rs w ere investigated:—

(1) A dding the flux (a) as a dried m ixture, o r (6) p re ­ fused an d re-g ro u n d ; (2) adding the flux (a) all with the charge, or (b) h a lf the q u an tity o f low oxidising pow er (1 p a rt by w eight cupric oxide, 4 p arts each oth er co nstituent) w ith the charge, an d the re m a in d e r (3 p arts cupric oxide, 4 p arts each o th er co n stitu en t) during the sup erh eatin g stage; (3) the tim e perm itted fo r reactions to occur betw een the m olten m etal and flux, an d (4) the effect o f different thickeners.

A ll m elts w ere deoxidised either w ith 0.05 per cent, p h o sp h o ru s o r w ith 0.1 per cent, alum inium . In each exp erim en t the m etal w as p o u red a t 1,150 deg.

C. + 20 deg. C., the tem p e ratu re being m easu red w ith a C h ro m e l/A lu m e l couple in a silica sheath p ro tected w ith a w ash o f alu n d u m cem ent or ganister. T hree m o u ld s w ere used, two of co n v en tio n al design giving sm all strip ingots (12 x 4 x f in. o r 12 x 2 x £ in.), the o th er a sm all billet m o u ld (Fig. 1) designed to give uni-directional cooling a n d thus m inim ise shrinkage defects. T h e strip m oulds w ere pre-heated to 100 deg.

C ., dressed w ith F ren ch chalk and inclined a t 30 deg.

to th e vertical fo r p ouring dow n the inclined edge directly fro m th e m elting pot. W ith the b illet m ould, cen tral-fu n n el p o u rin g a t a ra te of \ lb. p e r second w as used. T h e base was h eated to 100 deg. C. and dressed w ith F re n c h chalk; the steel cy lin d e r an d the o u ter fireclay in su lato r w ere p reh eated to 700 to 800 deg. C.

Billets an d ingots w ere an n ealed fo r 4 hrs. a t 750 deg. C ., th en sectioned an d tested as in Figs. 2-3.

Som e o f the results o f these experim ents are sum m arised in T a b le I.

T he flux fu m ed b ad ly a t o p e ratio n al tem p eratu res an d attack ed the m elting p o t slightly, th o u g h m uch less th a n highly basic fluxes o f the L epp type. D iffi­

cu lty w as also en co u n tered in thickening the flux for rem o v al, a th in sem i-tran sp aren t lay er re m ain in g on the m etal surface a n d causing fine slag-traps in the billets. In spite o f these disadvantages, th e flux effected a definite degassing actio n on the m etal, as show n by the very satisfactory m echanical pro p erties o f the

308 FO U N D RY TRADE JO U R N A L A U G U ST 17, 1944

Development o f a Flux Degassing Process

strip ingots, all. o f w hich w ere ro lle d h o t or cold w ithout cracking. T he p ro p erties o f the billets are p a rticu larly n o tab le, being high and u niform across the section. M a cro stru ctu res an d m ic ro stru ctu re s also show ed m ark ed freed o m fro m p o ro sity except a t the top centre. S crap charges gave results co m p arab le w ith virgin m etals. A nalyses o f these bro n zes show a slight tin loss, w hich is discussed later.

P re-fusing the flux w as fo u n d to b e p re fe ra b le to using the “ dried ” m ixture, since th e la tte r on heatin g

c o n tin u e d to. evolve w ater v a p o u r u p to fu sio n tem ­ p eratu re. A d d itio n o f the flux in tw o stages gave no a d v an tag e over ad d in g all w ith the ch arg e. The tim e w hich co u ld be allow ed fo r re a c tio n betw een m etal an d flux was fo u n d to be restric te d by the necessity of o b tain in g the c o rre c t casting te m p e ra tu re an d av o id ­ ing o v e r-o x id a tio n (T ab le I).

T h ick en ers h a d little actio n .on the p ro p e rties of the m etal ex cep t in the case o f co m m e rcial b o n e ash. This caused a v io len t re ac tio n a n d gave gassy m eta l w ith in ferio r properties,, e.g., tensile stren g th 15 to 17 tons per sq. in., w ith 15 to 30 p e r cent, e lo n g a tio n , c o m ­ pared w ith 22 to 24 tons per sq. in.. w ith 50 to 60

Fig. 1.— Me t a l i s Po u r e d Th r o u g h a Sa l a m a n d e r Fu n n e l In t o a St e e l Cy l i n d e r, w h ic h i s Su r- R O U N D E D B Y

L A T O R A N D Al u m in i u m Ba s e.

a Fir e c l a y In s u- St a n d s o n A N Br o n z e Ch il l

Fig. 2 .— Pl a n o f Bil l e t, Sh o w in g Me t h o d o f Se c t io n i n g f o r Te s t s. Ke y: R = Ro l l in g Sp e c im e n; O = Ou t s i d e Te n s i l e Sp e c im e n; C = Ce n­ t r a l Te n s i l e Sp e c i m e n.

Fig. 3 ( Rig h t).— Me t h o d o f Se c­ t i o n in g St r i p In g o t s. Ke y: A

= Sp e c im e nf o r Ro l l in g Te s t; B & C = Te n s i l e Sp e c i m e n s; D -F = Mic r o s p e c i m e n s; G = Sa m p l e f o r An a l y s i s; H K a n d

L M = Nic k e d a n d Fr a c t u r e d f o r Vi s u a l Ex a m i n a t i o n.

D E

Ta b l e I . -—Effect of Reaction T im e . Reaction

time.

Appearance of m elt after deoxidation.

Characteristics of ingot.

Rolling properties.

A nnealed 16 hrs. a t 750 deg. C.

5 m inutes Too cold to pour. — —

10 m inutes Surface of m etal cleared well.

Temp. 1,250 deg,, 0.

Surface blowing. Slight pinhole porosity in m icrostructure.

Cold rolled 80 per cent, w ithout cracks. H ot rolled w ith trace of edge cracking.

20 m inutes Surface did n ot c le a r; m etal over-oxidised. Temp, above 1,300 deg. C.

Less surface blowing. More interdendritic porosity. Crys­

tals of SnO , in m icrostructure.

Cracked badly in cold an d hot rolling.

A U G U ST 17, 1944 FO U N D RY TRADE JO U R N A L 309 per cent, elo n g atio n , o b tain ed w ith o th er thickeners.

The gassing w as a ttrib u te d to residual organic m atter in the b o n e ash, and w as elim in ated by re-calcination of the la tte r b efo re use. T h e fritted m ixtures thickened the flux m ore read ily th a n the sand or bone ash alone, b u t otherw ise gave no im provem ent.

F ro m the resu lts o f these experim ents, the follow ing melting p ro ced u re w as ad o p ted fo r fu rth e r investiga­

tions. T h e m etal was ch arg ed with pre-fused flux (1 oz.

per lb. o f m etal); w hen m o lte n the flux w as draw n aside an d h a lf the ch o sen deo x id an t (0.05 per cent, phosphorus as 15 p er cent, p h o sp h o r-co p p er, or 0.1 per cent, p u re alu m in iu m ) was added, to g eth e r with the req u ired a m o u n t o f tin. A fte r 10 to 15 m in u tes’

superheating, the flux w as m ixed w ith the m etal, allowed to sep arate, th ickened with dried sand, and removed com pletely fro m the su rface o f the m etal.

The rem ain in g d eo x id an t w as then added, stirred well in, and the m etal skim m ed ag ain a n d allow ed to cool to the casting tem p eratu re.

The Effect o f Som e Variations in F lu x Com position A n u m b er o f fluxes (T able II) w as p rep ared by m odifying the o rig in al co m position in o rd e r to elim inate the disad v an tag e o f the la tter and to study the effect of v ario u s c a rrie r m aterials (borfc acid, borax, sodium fluoride, etc.), e ac h w ith two c o n c e n tra ­ tions o f c o p p er oxide, on the p ro p erties o f chill-cast tin bronzes. W ith each flux, strip ingots of 14 per cent, tin b ro n ze fro m virgin m etals and o f 12 per cent, bronze fro m scrap w ere p re p are d by the m elting and casting p ro ced u re given in the previous section. One com parative m elt w as m ad e w ithout flux. Ingots w ere

an n ealed fo r 16 hrs. at 750 deg. C., an d sectioned and tested as show n in Fig. 3.

F luxes co n tain in g sodium chloride or boric acid were a b an d o n ed a fte r prelim in ary ex am inations, since the fo rm er caused severe fu m in g and slag-traps in the m etal, w hile sub stitu tio n o f b o rax fo r boric acid gave cleaner m elts, especially with scrap charges.

T h e fluxes c ontaining sand an d b o rax are p a rtic u ­ larly n o tab le; they a re non-fum ing, easy to thicken fo r rem oval, an d have no attack on the salam an d er pot. R ep eated use o f this type of flux h as confirm ed th a t the p ot gives as m an y heats as w hen n o flux is used.

A nalyses o f the bronzes show a slight tin loss and a relatively high p h o sp h o ru s loss w ith all fluxes, b u t ap p reciab ly greater in those of hig h er co p p er oxide co n ten t. T his suggests th a t the latter reacts w ith the tin in the m elt: 2C uO + Sn v N S n 0 2 -f 2Cu, and th a t the tin oxide fo rm ed is distributed betw een the m etal and the flux. T h a t ab so rb ed by the m etal prevents h y d ro g en a b so rp tio n , and is eventually red u ced by the deoxidant, thus accounting fo r the high p h o sp h o ru s loss. T h e p o rtio n ab so rb ed by the flux rep resen ts the observed loss in tin fro m the

bronze.

T he m icro stru ctu res o f flux-treated ingots all show less p orosity th a n the u n trea te d one, the sand-bearing fluxes being the best in this respect. T h e fluxes have no effect on the distrib u tio n o r a m o u n t of the eutectoid, w hich in all ingots varies fro m isolated areas in the centre to in tercrystalline films at the outside. T he shallow surface layer of fine chill crystals has a higher

T a b l e I I .— Compositions and Characteristics of Fluxes Used.

Composition parts by weight. Relative fluidity

(am ount of

A ttack on salam ander pot.

Flux. Cuprie oxide.

Sodium chloride.

Sodium fluoride.

Boric acid glass.

Fused borax.

Red sand (dried).

sand needed for thickening)

in oz.

per lb.

Fuming.

CFA* .. 3 4 4 4 — — Could n o t be

thickened ef­

fectively (12)

Slight Severe.

FA* .. 2 — 4 4 — ■—■ 10' Slight Less th an CFA.

CF* . . 2 4 4 — ■—• ■— A s C F A (lO ) .. Slight Severe.

B.l . . 4 __ __ — 8 — 6 Moderate , None.

F .l 4 — 8 — — — 8 Slight Considerable.

Less th an CFA.

F B .l .. 4 __ 4 — 4 — 6 Moderate Slight.

SB.l .. 5 __ — — 1 4 2 None None.

S F .l .. 5 --- < 1 — — 4 2 Very slight Very slight.

S F B .l. . 4 --- 4 — .2 5 3 Negligible Very slight.

B.2 .. 2 __ __ __ 10 — 8 Considerable None.

F.2 .. 2 __ 10 — — .— 10 Slight Severe.

FB.2 . . 2 --- 5 — 5 — 8 Slight Moderate.

SB.2 .. 2 --- — — 4 6 3 None None.

SF.2 .. 2 --- 4 — —• 6 3 Negligible Very slight.

SFB .2. . 2 2 2 6 3 Negligible Very slight.

^Abandoned after prelim inary experiments.

310 FO U N D R Y TRAD E JO U R N A L A U G U ST 17, 1944

Development o f a Flu x Degassing Process

eutectoid c o n te n t ow ing to the severe chilling action o f the m ould. A ll specim ens w ere fre e fro m n o n - m etallic inclusions.

T h e density o f the chill-cast ingots does n o t v ary w ith flux com p o sitio n , b u t all fluxed sam ples have higher densities th an the u n tre a te d one. A fte r a n n ea l­

ing, sam ples m elted u n d e r siliceous fluxes are o f ra th e r h ig h er density th a n the others. T h e co p p er ox id e c o n ten t o f the flux h as no effect on these, b u t w ith sand-free fluxes, th o se o f h ig h er co p p er oxide co n ten t give slightly h ig h er densities.

T h e slight decrease in density w hich occurs during an n ealin g is p ro b a b ly caused by com pletion of the re actio n 2 H 2 + S n 0 2 — ^ 2 H 20 + Sn betw een

ab ly cau sed by sh rin k ag e cavities. T h e siliceous fluxes again gave the best results. T h e ingots p re p a re d fro m scrap show ed less crack in g in all cases, b u t th is is p ro b a b ly a ttrib u ta b le to th eir low er tin co n te n t. The u n tre a te d ingots, b o th v irg in an d scrap, w ere m arkedly in fe rio r to th e flu x -treate d ones.

T h e v ariatio n s in m ech an ical p ro p e rties o f rolled strip w ith the flux used (w hen allo w an ce is m ad e fo r v a ria tio n s in tin co n te n t) a re in the sam e o rd e r as the free d o m fro m crack in g d u rin g h o t ro llin g , i.e., the siliceous fluxes a g ain give the b est results.

T h e resu lts o f these investig atio n s show th a t the fluxes co n tain in g only san d , b o ra x , a n d c o p p e r oxide a re the m o st satisfac to ry . T h ey a re ch ea p , n o n ­ fum ing, easy to thicken fo r re m o v a l, a n d give the g reatest im p ro v em en t in so u ndness and m ech an ic al and w o rk in g p ro p e rties o f th e b ro n z e. F u r th e r investiga- T a b l e I I I .—•Effert of deoxidant.

P roperty tested. Deoxidised with phosphorus. D eoxidised w ith alum inium .

Molten m etal characteristics.

Surface of strip ingots.

Tensile te s t on 10 per cent, tin billet, as cast.

Tensile te s t on annealed specimen of 14 per cent, tin strip ingot

Average density of 10 per cent.tin billet r M icrostructure of 9 per cent, or 10 per \

cent, tin billet (flux FB), annealed.

Cold ro llin g ; 9-14 per cent, tin strip ingot, annealed.

H o t rolling ; strip ingots 9-14 per cent, tin.

Surface clear. M etal fluid.

“ Blowing ” on pouring edge.

23-24 tons per sq. in. 45-65 per cent.

extension.

27-29 tons per sq. in. 60-70 per cent.

extension.

Cast . . 8.91 grm. per c.c.

A nnealed . . 8.89 grm. per c.c.

Uniform a. No inclusions.

No cracking to 90 per cent, reduction.

Traces of edge cracking, increasing w ith tin content.

Surface covered w ith oxide skin. Metal pours very sluggishly.

No “ blowing.”

21-23 tons per sq. in. 30-50 per cent, extension.

23-27 tons per sq. in. 25-50 per cent, extension.

Cast . . 8 .92 grm. per e.c.

A nnealed . . 8 .92 grm . per c.c.

Occasional trap p e d oxides. Brown inclusion.

No cracking to 90 per cent, reduction.

No cracking in an y composition.

residual h y d rogen a n d oxygen in the m etal. S crap m elts give slightly h ig h er densities th a n the c o rre ­ sponding m elts fro m virgin m etals.

T h e resu lts o f tensile tests w ere n o t directly c o m ­ p a rab le, due to th e slight v a ria tio n s in tin content.

T h ese v ariatio n s w ere assessed by testing bronzes co n ­ tain in g 10 to 14 p e r cent, tin, all p re p are d u n d e r the sam e flux (san d -b o rax -co p p er oxide); A g rap h o f stren g th against tin c o n te n t show ed th a t an increase o f 1 per cent, tin p ro d u ced a n increase in tensile stren g th of a p p ro x im ate ly 1 to n p e r sq. in., b u t th ere was a p p rec i­

ab le change in ex tension over this range of com posi­

tion. W h en this effect is tak e n in to th e account, th ere is no consisten t v a ria tio n in strength w ith th e flux used, b u t elo n g a tio n values are consistently hig h er w ith th e siliceous fluxes. T h e scrap m elts a re n ot in ferio r to virgin m elts w hen allow ance is m ad e fo r the difference in com position.

A ll th e flux-treated ingots c old-rolled to 80 p e r cent, re d u ctio n w ith o u t cracking, b u t in h o t ro llin g fro m 750 deg. C. th ey develo p ed slight edge cracking and, in som e cases, fine cracks alo n g th e face-centre, prob-

tion o f the effect o f c o p p e r oxide c o n te n t o f the flux in relatio n to d e o x id a tio n p ro c ed u re is in progress.

Comparative Effect o f Phosphorus and A lum inium as D eoxid an ts

A n u m b er o f ex p erim e n ts re p o rte d in the preceding sections w ere re p ea te d w ith a lu m in iu m as deoxidant instead o f p h o sp h o ru s. T h e c h ief difference betw een th e tw o a re su m m arised in T a b le III.

T h e h ig h er d ensity a n d ab sen ce o f an y ch an g e in density on a n n ealin g , to g eth e r w ith th e low er tin loss in b ro n zes deoxidised w ith a lu m in iu m , suggest th a t it rem oves th e oxygen fro m the m elt m o re efficiently th an does p h o sp h o ru s, so th a t no oxygen is a v ailab le to re ac t w ith th e resid u al h y d ro g e n d u rin g solidification an d su b seq u e n t annealing. F ro m the m etallu rg ical view point, how ever, a lu m in iu m is n o t a satisfacto ry su b stitu te fo r p h o sp h o ru s, ow ing to the fo rm a tio n of oxide skins w hich becom e e n tra p p e d in the m etal an d im p air the m ech an ical p ro p erties. In addition to these trap p e d oxides, a h a rd , b ro w n inclusion, p ro b a b lv s o m e

(C o n tin u e d on page 312, c o lu m n 1.)