Foundry Trade Journal : with which is incorporated the iron and steel trades journal, Vol. 72, No. 1467

T f ii hM rj»y

EST. 1902 T R A D E J O U R N A L

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

N o . 1467. S E PTEM B ER 28, 1944 [a"™.!

R e giste re d a t th e G.P.O . os o N e w sp ap e r- Offices : 4 9 . W e llin g to n S tree t, S tra n d , London, W .C .2 . |_ l n j O v e rs ee s, 21 / - (P re p ais

V O L . 74. i C op y id . By Poet (

al Su b scrip tio n . Hon

)ULDING

^CHINE C° LTD

F L U X IT O L for Perfect Castings or Ingots C U P O L 1 N E for Furnace or Cupola

Repairs

E F F IC IE N T service, w ith consultation R O B S O N R E F R A C T O R IE S L IM IT E D

M A N S F I E L D MOULDING SAND

ERSHAM. KENT.

4 7 , C o n i s c l i f f e R o a d , D a r l i n g t o n 'P hone : 2441 ’ G ro m s : C u p o l i n e

0 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 D

A L B IO N (M a n s fie ld ) S A N D C O .

& W . W A R D ° L T D . *">«” > Works, SHEFFIELD

T e le p h o n e s : S h e ffie ld 26311 ( IS lin e s ) M a n s fie ld 371

PIG IRON _{SAND CAST}

MACHINE CAST

HEMATITE

SPECIAL HEMATITE

(Suitable fo r Malleable Trade)

BASIC

UEST KEEN BALDWINS

IRON £, STEEL CO LTD.. PORT TA LBO T.

aND TESTING

•r C atalogue o f Testing M achines to

IS N O W VITAL TO ALL FOUNDERS TO ECONOMISE SAND A N D MAKE BETTER

:ss...

EYRE

T a n d e m W h i t e M e t a l s • G u n - M e t a l P h o s p h o r B ro n z e and A lu m in iu m In g o ti C h i l l C a s t P h o s p h o r B r o n z e R o d s T A N D E M W O R K S . M E R T O N A B B E Y . L O N D O N . S . W . I ( M i t c h a m 2 03 1)

FOUNDRY TRADE JO U R N AL SEPTEMBER 28, 1944 —

\ * m

L I'

N

\

it

k fa i thV

RO TARY FURNACES

FIRED BY FUEL OIL

TOW NS GAS

“ PULVERITE ” OR

CREOSOTE PITCH

MIXTURE

STEIN & A T K IN SO N LTD

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 3 1 I I - ; M E T A S T E I N A , P H O N E , L O N D O N

C A M B O R N E EN G LAN D

I V»AAI I D V / K l l C ^ • ł

S U p p i y ’ P h o n e : C a m b o r n e 2275

’ G r a m s : A i r O f f i c e :

B R O A D S T R E E T H O U S E E .C .2

y a • ’Grams : A ird rill, Cambor

Z i l G A i r L o n d o n O f f i c e :

R e p ro d u ce d b y c o u r­

te s y o f M e s s r s . R o b e rt H y d e & Son, L td ., N o rth S ta ffo r d Steel F o u n d ry, Stoke-

o n -T re n t.

SEPTEMBER 28, 1944

• • • M B i • • •

FOUNDRY TRADE JO URNAL 3

a< a a • • • ■ ■ • • » ■ ■ ■ • • © HHH

I B R IT IS H PIQIROW S L IM IT E D I •

MIDHILL ^m

A L L M I N E

S PEC IA L PIG IRONS

GLENHILL

_

• • • M M B

B E S T AFTER T E S T

L I T T L E C O U R T P Y R F O R D COMMON

w O K I N Q

T eleg ra m s : Iro n o b rit, Phone.

W o k in g T e le p h o n e : Byfleet

3100

I

I

• • • 0 • • • — » • • — • • • ^ • • • —

— _— —^

:_ e*Lic

I

4 FO UNDRY TRADE JO U R N AL SEPTEMBER 28, 1944

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 .

GLYSO CORE M A K IN G P R O D U C i

ARE INSEPARABLE FROM FORDATR NEW-TYPE MIXERS B- CORE EXTRUSION MACHINES .

THE FOROATH ENGINEERING C!L"

T E I E P H O N E :

WEST BROMWICH 0549 (2 LINES)

H A M B L E T W O R K S W E S T B R O M W I C H

SEPTEMBER 28, 1944 FOUNDRY TRADE JOURNAL

M ix in g T im e - - 2 M in u te s . D is c h a rg in g T im e - Vi M in u te .

The “ N E W - T Y P E ” F O R D A T H M IX E R S are made in FIVE sizes, fro m 20 lbs. to I to n per batch.

6 FOUNDRY TRADE JO URNAL SEPTEMBER 28, 1944

PRODUCTION PRODUCTION PRODUCTION

The main object of nearly every foundry in these production. Sterling Boxes will help to gain this lightness enables moulders to put down more moulds per day. Their accuracy reduces the number wasters. Their durability prevents stoppage^of work due to breakage of boxes.

• • c

A ll kin ds and sizes o f castings in a ll kinds o f m etal are made in Sterling Boxes.

Te lep ho ne:— BEDFORD 5338-9 T e l e g ra m s :— STERFLASK, BEDFORD

days is increased objective. Their

STERLING FOUNDRY SPEC

B E D F O R D

SEPTEMBER 28. 1944 FOUNDRY TRADE JOURNAL

“ ' * W W

c u p o las core an d m o uld ja rr ro llo v er san d p re p a rin g sa n d m ix in g m ills ro tary sand d ryers K o y e r sa n d m ix e rs d ry in g sto ves m ach in es plan ts san d d isin teg rato rs po rtab le m o u ld d ry e rs

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

FOUNDRY TRADE JO U R N AL SEPTEMBER 28, 1944

I f only by easing the burdens o f la b o u r, lig h t alloys w ill p a y th eir w ay. Besides this they w ill save power, overcome corrosion. Used archi­

tectu rally they w ill symbolise

a better a g e when lightn ess and

cleanliness go with strength

and beauty. These, too, are

reasons why ‘ 1NTAL ’ are so

p r o u d t o b e m a k e r s o f

alum inium alloys for every

conceivable purpose.

SEPTEMBER 28, 1944 FOUNDRY TRADE JOURNAL 9

UTILISES ELECTRICITY AS TME DIRECT POW ER FOR HIGH PRODUCTION W O R K

ROLL-OVER TYPE

MAGNETIC MOULDING MACHINES

BRITISH PATENT No. 111777.

B.l. M ag n e tic M ou ld in g M ach ines h a v e fou r o u tsta n d in g fe a tu re s w h ich re su lt in fo u r vitally im p o rta n t p ro d u c tio n fa c to rs —s p e e d , ac c u ra c y , ec o n o m y a n d re lia b ility . By th e utilisation of e le c tric ity a s th e d ire c t p o w e r m ed iu m , th e m axim um o u tp u t of a c c u ra te m o u ld s is e c o n o m i­

cally a tta in e d w ith th e m inim um of m anual effort.

W ith ‘' ro llin g -o v e r ’ ’ p e r fo rm e d b e f o re s q u e e z in g , all p ossib ility of d isto rtio n is e lim in a te d . A u to ­ m atic s trip p in g o n to th e c o n v e y o r also allow s th e o p e r a t o r 's attentio n to b e c o n c e n tra te d fully on m o u ld p ro d u c tio n . W rite fo r leaflet M .115.

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

P R E S C O T — L A N C S . T e l e p h o n e P R E S C O T 6 5 7 1 .

N.R.S. HEATING UNITS

2 B ric k b u ilt f o r l a r g e S to v e s

50°/D less fuel, half the drying

time ,

and perfect Cores & Moulds

U S IN G C O K E B R E E Z E 1 S e lf-c o n ta in e d fo r S to v e s u p to 2,000 c u b ic fe e t O R C O K E R E FU S E

Sole S u p p l ie r s :

MODERN FURNACES AND STOVES LTD.

BOOTH STREET HANDSWORTH ■ BIRMINGHAM, 21

10 FOUNDRY TRADE JO U R N AL

The vital needs of war-time production have made u n ­ precedented dem ands upon castings. W ithout the re­

search work on pig iron carried out in th e past, they could not have been fulfilled.

High duty castings will play an increasingly im portant part in reconstructiom after the war and pig irons, made f r o m t h e b e s t o f r a w

f o r C a s t i n g s

materials, treated by the Bradley Spun-refining P ro­

cess and subject to chemical analysis and mechanical and metallurgical test at every stage of production, will make possible the coming renaissance of Iron. We shall be glad to discuss the future of high duty castings in relation to your own requirem ents.

B R A D L E Y & F O S T E R ltd DARL AS TO N . SOUTH S TA FFS

M A K E R S O F

{

Spun-refined pig irons.

S pun-refined alloy pig irons.

B lended “ All Mine ” pig iron.

H igh carbon steel pig iron.

F ire-resisting pig iron.

SEPTEMBER 28, 1944 FOUNDRY TRADE JO URNAL II

KEITH

BLACKMAN

MAN-COOUNC

FA N S_____

For blow ing cool a ir at w orkers engaged in hot spaces at furnace fronts, etc. O f heavy, all- steel co nstructio n , designed to stand up to hard-w orking conditions. Can be adapted fo r suspension w here flo o r space is lim ited.

W r i t e fo r C atalogue V-201

K E IT H B L A C K M A N L T D ., M IL L M EA D R O A D , L O N D O N , N.I7. T N . : T O T T E N H A M 4522. T A . : “ K E IT H B L A C P H O N E L O N D O N .”

l l 0 * U I D

/ i S ® VICTOj - ^ M ^ g

c o n c e n t r a t e s X R A Y F I L M P R O C E S S I N G C H E M I C A L S

EASIER, m ore c o n ve nien t to m ix —you sim ply p o u r these liq u id concentrates in to y o u r tanks and add w a te r. SPEEDIER film process­

in g —developm ent in 3 m inutes at 68°F. and fix in g in less than I m in ute . A lte rn a tiv e ly you can reduce X -ra y exposures by 20% to 25%

to conserve tube life . E C O N O M IC A L — lo n g er-lasting Superm ix so lu tio n s w ill process up to 75% m ore film s than w ith conventional p o w d e r chemicals. A nd, o f course, Superm ix developm ent w ill ensure th e u tm o st in film contrast, density and diagnostic detail.

P R I C E S D e v e l o p e r F i x e r

T o m a k e I g a ll o n ... ... ... ... 6 / 6 5 /6

„ „ 2 „ I I/- 91-

„ „ 5 „ 2 7 / - 2 3 -

VICTOR X -R A Y CORPORATION LTD.

15-19 Cavendish Place, London, W . l L A N gham 4074

B i r m i n g h a m 55 P e rs h o re S tr e e t. M id la n d 21 10 G la s g o w — 34 W e s t G e o rg e S tr e e t. D o ug la s 1884 M a n c h e s t e r — M iln e B u ild in g s , 66 M o s le y S t. C e n tr a l 0 27 5 B r i s t o l — 73 Q u e e n S q u a re . B ris to l 2 0 8 9 0

B

GREATER

E C O N O M Y

CONVENIENCE

12 FO UNDRY TRADE JOURNAL SEPTEMBER 28, 1944

S A N D S L I N G E R S

Illu stration sh o w s S a n d s lin g e r o f s t a t io n a r y t y p e w ith sp e c ia l riddling g e a r a n d m a in

arm s u ita b le for r o ta tio n th r o u g h 3 6 0 °.

M a ch in e is fed by o v e r h e a d b e lt c o n v e y o r or e le v a to r .

A s tu r d y r e lia b le u nit b uilt to m e e t fo u n d r y c o n d itio n s .

FO U N D R Y PLA N T & M A C H IN E R Y LTD. 113 ST-

JDRY TRADE JOURNAL 13

T H R E E - M O T O R W A L L C R A N E

P A T E R S O N H U G H E

E N G I N E E R I N G C O M P A N Y LI MI TED

s

B e d fo r d H o u s e , B e d fo r d S t., S t a n d , W . C . 2 W y n d fo r d W o r k s , M a r y h ill, G la s g o w , N . W .

T e m p le B a r 7 2 7 4 /6 M a r y h ill 1 72/3

YCLONE

FA N S

P V T A I R TO W O R K

MATTHEWS & YATES

H e a tin g and V en tila tin g E ngineers L S W I N T O N ( Manches t er ) & L O N D O N

Telephon«. : SWInton 2273. (4 line»). LONDON. Chancery 7823 G L A S G O W • L E E D S • B I R M I N G H A M • C A R D I F F

F u ll Technical D a ta sup plied on quoting ref. F E / I

n m m

istablishecf 1902

-g«rrorrsnn

WITH WHICH ‘IS INCORPORATED T H E I R O N A N D S T E E L T R A D E S ¡O U R N A L

4 9 , W e llin g to n S tr e e t, L o n d o n , W .C .2 .

W A R T IM E A D D R E S S t o w h ic h a ll c o m m u n ic a tio n s sh o u ld be s e n t l __

3 , A m e rs h a n ri R o a d , H I G H W Y C O M B E , B u c k s . 'G ra m s : " Zacatocas, H ig h W y c o m b e ."

'P h o n e i H IG H W Y C O M B E 1792 (3 lin o s ).

P U B L IS H E D W E E K L Y ■ 21s. p e r a n n u m (H o m e and O v e rs e a ! )

O F F IC IA 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 lt iH e r b e r t W r ig h t , T h e B u tte r le y C o m p a n y . R ip le y , n e a r D e rb y . S e c re ta ry i V . D e lp o r t, 2, C a x to n S tre e t, W e s tm in s te r . S .W .I.

P o rt/c /p o t/n g Associations l B r itis h B ath M a n u fa c tu re rs ' A s s o c ia tio n B r itis h Ir o n fo u n d e r s ’ A s s o c ia tio n ; B r itis h M a lle a b le T u b e F ittin g s A s s o c ia tio n ; C a st Ir o n A x le b o x A s s o c ia tio n ; C a st Iro n C h a ir A s s o c ia ­ t io n ; C a st Iro n H e a tin g . B o ile r and R a d ia to r M a n u fa c tu re rs ' A s s o c ia tio n ; C a st Iro n S e g m e n t A s s o c ia tio n ; G re e n sa n d P ipe F o u n d e rs ’ A s s o c ia tio n o f S c o tla n d ; Ir o n fo u n d e r s ’ N a tio n a l C o n fe d e ra tio n ; N a tio n a l A sso cia ­ t io n o f M a lle a b le Iro n fo u n d e rs ; N a tio n a l In g o t M o u ld A s s o c ia tio n ; N a tio n a l Ir o n fo u n d ln g E m p lo y e rs ’ F e d e r a tio n A s s o c ia tio n o f A u t o ­ m o b ile a n d A llie d H ig h D u t y I r o n f o u n d e r s ; B r it is h C a st Ir o n R e search A s s o c ia tio n ( a f fi lia t e d ) ; B r itis h G r i t A s s o c ia tio n ( a ffilia te d ) ; F lu s h in g C is te r n M a k e rs ’ A s s o c ia tio n (a ffilia te d ) ; I n s t it u t e o f B r itis h F o u n d ry m e n ( 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 , 194 3-44 : D . S h a rp 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 to n . A c tin g S e c r e ta r y , 1. B o lto n S aint J o h n S tr e e t C h a m b e rs , D e an sg ate . M a n c h e s te r 3.

B R A N C H E S

B irm in g h a m , C o v e n tr y a nd W e s t M id la n d s I A . A . T im m in s , 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 is t o l a n d W e s t o i E n g la n d ; A . H a re s, 2 0 . G r e e n b a n k R o a d , H a n h a m , B r is to l. E. M id la n d s ; S. A . H o r to n " T h r e e , " M o s ty n A v e n u e , L lt tle o v e r , D e rb y . Lancs : H . B u c k ­ le y , E lle s m e re , N o r f o lk A v e n u e , B u r n le y . L o n d o n ; V . C . F a u lk n e r, 3. A m e rs h a m Road. H ig h W y c o m b e . M id d le s b ro u g h (pro te rn .) : J. K . S m ith s o n , N o rth -E a s te rn Iro 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 s tle -u p o n -T y n e : C . L ash ly, S ir W . G . A r m ­ s tro n g , W h it w o r t h & C o . ( Ir o n fo u n d e r s ), L td ., C lo se W o r k s , G ateshead S c o ttis h i J. B e ll, 60, S t. Enoch S qu a re, G la sg o w . S h e ffie ld : T . R. W a l k e r , M .A ., E n g lis h S te e l C o r p o r a t io n , L t d . , S h e ffie ld . W a le s and M o n m o u th i A . S. W a ll, 14, P a la ce A v e n u e , L la n d a ff, C a r d iff. W e s t R id in g o f Y o r k s h ir e : D o u g la s J e p s o n , M .S c., 9 , A m b le s ld e A v e n u e , B ra d fo rd . S o u th A fr ic a ; B. P. S k o k , M u tu a l B u ild in g , Jo h a n n e s b u rg .

S E C T IO N S

B u r n le y I H . B u c k le y , E lle s m e re , N o r f o lk A v e n u e . B u in le v , Lancs.

Cape) T o w n ; K . Z w a n z l- e r , P .O . B o x 346, C a p e T o w n , S. A fr ic 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 s w ic h F a lk ir k : T . R. G o o d w in . " V le w fie ld ,” F a lk irk Road, 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 c h n ic a l C o lle g e , L in c o 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 s e ll, J. S to n e & C o ., L td ., L o n d o n . S e c r e ta rie s : H e a th c o te & C o le m a n , 2 5 , B e n n e tts H il l, B irm 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 a ld e n t i W . H . W h it t le . W . H . W h it t le , L im ite d , Eccles, nea r M a n c h e a te r. C h a irm a n i W . T o d d , P a r k in s o n S to v e C o ., L td . . S te ch - f o r d , 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 tr e e t, R lc k m a n s w o r th , 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. Fra n ce, A u g u s t's , L im ite d , T h o r n T re e W o r k s , H a lifa x . H o n o r a r y S e c r e ta r y : K . W . B rid g e s . A sslsta n c S e c re ta ry i Miss L . C o x . 5 2, S u r b ito n H il l 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 s id e n t I W . E. C le m e n t, C .B .E ., M o rfa F o u n d ry , N e w D o c k . L la n e lly S e c re ta ry i J. D . D . D a v is , I, S t. James G a rd e n s , 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 lv s c h u r c h , B ir m in g h a m . ’ P h o n e a n d 'G r a m s : R e d d lt c h 7 l 6 . S c o ttis h L a b o r a t o r i e s F o u n d r y T e c h n ic a l I n s t it u t e . M e e k ’ s R o s d , F a lk ir k . (P h o n e i 332.1

14 FO U N DR Y TRADE JO U R N A L SEPTEMBER 28, 1944

T h e n e ed 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 e m 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 s t 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 ­ tio 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 to p o in t to th e o n ly sa tisfa c to r y s o lu t io n t o all th e s e p r o b le m s —

MECHANISATION

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 ad 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 c to 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 h ave an y b earin g o n th e p r o b le m .

In o th e r w o r d s c o n s u lt : —

“ The Specialists in Foundry Mechanisation”

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

Set the Standard b y which Foundry Plant is ju d g e d .”

L IM IT E D

’P h o n e s : 6 1 2 4 7 & 8

HALIFAX , ^ENGLAND

Foundry Trade Journal, September28, 1944

established !$02

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

WITH WHICH H INCORPORATED T H E IR O N A N D STEEL TRADES JO URN AL

Vol. 74 Thursday, September 28, 1944 N o. 1467

“ P re -W a r” Quality

In th e p e r io d b e tw e e n th e tw o w a rs , a n y th in g d e sig n ated “ p r e - w a r ” w a s o f te n i n te r p r e te d as being o f s u p e r io r q u a lity . T h e r e w e re , o f c o u r s e , ex cep tio n s, s u c h as m o to r - c a r s , a ir c r a f t a n d g o o d s which re s p o n d re a d ily to f a s h io n c h a n g e s . W ith the d e te r io r a t io n o f c o n s u m e r g o o d s d u r in g th e second w o r ld w a r , th e r e is m o r e t h a n a p o s s i­

bility o f th e e s ta b lis h m e n t o f a s im ila r s ta te o f affairs in th e p o s t- w a r e ra . P r e ju d ic e is n o d o u b t an i m p o r ta n t f a c t o r , y e t it is u n d e n ia b le t h a t lo ss of c r a f ts m a n s h ip d u r i n g s e rv ic e u n d e r th e c ro w n , coupled w ith th e e x is te n c e o f m a r k e ts h u n g r y f o r any ty p e o f s a le a b le g o o d s , c r e a te s c o n d itio n s f o r m aking o f q u a n tity r a th e r th a n q u a lity . C o n s e ­ quent u p o n th is m a n y lin e s o f m a n u f a c tu r e a c q u ire a r e p u ta tio n a s b e in g i n f e r io r to p r e -w a r . C e r ta in industries b e n e fitin g f r o m t h e s o lu tio n o f w a r p ro d u c tio n p r o b le m s , a r e q u ic k ly a b le to sa tis fy public o p in io n t h a t th e a p p e lla tio n “ p r e -w a r ” is so d e ro g a to ry t h a t o n ly s h o r ta g e o f c a s h a llo w s th e article to r e m a in in u se .

In th is b r a v e n e w w o r ld lo o m in g u p o n th e horizon, h o w w ill t h a t sp e c ia lis e d g r o u p o f in d i­

viduals w h o b u y c a s tin g s r e g a r d th e p r o d u c t o f th e foundry in d u s tr y ? W ill th e a d je c tiv e “ p r e -w a r ” be re g a r d e d b y th e m as d e n o tin g a h ig h le v e l o f quality n o w n o lo n g e r o b ta in a b le , o r ju s t a m e m o ry of a s e m i-in s p e c te d m a te r ia l o f u n c o n tr o lle d p r o ­ perties? I t a ll d e p e n d s o n th e m a s s o u tlo o k o f the w h o le o f th e f o u n d r y in d u s tr y o n its p ro d u c ts . If its c h ie f a g e n c ie s o f p u b lic ity — a n d th e r e a re m any— a r e c o n v in c e d t h a t th e in d u s tr y a s a w h o le has p ro g re s s e d a u f u r e t a m e s u r e w ith th e a e r o ­ plane, ta n k , g u n , r a d io a n d o th e r e n g in e s o f w a r, then a n d th e n o n ly w ill p o s t- w a r c a s tin g s b e r e ­ garded a s b e in g o n a h ig h e r p la n e th a n p re -w a r.

Mr. J. F . K a y s e r , in h is P r e s id e n tia l A d d re s s to the L o n d o n B ra n c h o f th e I n s titu te o f B ritish F o u n d ry m e n (p r in te d e ls e w h e re in th is issue), stro n g ly a d v is e d e v e ry f o u n d r y c o n c e rn to a c q u ire an X - r a y a p p a r a tu s as a m e a n s o f e n s u rin g a n d m a in ta in in g q u a lity . N o w , K a y s e r is n o t a c tiv e ly en g ag e d in f o u n d r y p ra c tic e , b u t a s a m e ta llu rg is t lo o k in g o n th e in d u s tr y fr o m w ith o u t. A s a te c h n ic ia n , h e sin c e re ly a p p r e c ia te s th e a d v a n ta g e s to b e d e r iv e d f r o m s c ie n tific c o n tr o l a n d in s p e c ­

tio n . T h e c o m m e rc ia l side o f b u sin e ss ta k e s its c u e f r o m su c h p r o n o u n c e m e n ts , a n d an a u th o r i t a ­ tiv e s ta te m e n t f r o m th e f o u n d r y in d u s tr y , t h a t x n u m b e r o f f o u n d r ie s n o w s u p p ly X - r a y in s p e c te d c a s tin g s, w o u ld h e lp m a te ria lly to p la c e c a s tin g s o n a h ig h e r level. B e tte r still, a s it is th e la rg e r ty p e o f c o n c e r n w h ic h uses o r w ill use X -ra y a p p a r a tu s , a s ta te m e n t th a t y p e r c en t, o f th e to ta l p r o d u c tio n o f B ritish f o u n d r ie s a r e so in sp e c te d w o u ld c a r r y s till m o re w e ig h t w ith th e b u y e r.

A n a llie d in d u s tr y to w h ic h c o m p a ris o n s o f p re - a n d p o s t-w a r q u a lity a re o f v ita l im p o r ta n c e is th e o n e u n d e r ta k in g v itre o u s e n a m e llin g . T h e ir p r o ­ d u c ts h a v e , a s r e la te d in th e la s t w a r, m a d e th is th e a d je c tiv e “ p r e -w a r ” a s a p p lie d to c o o k e rs , m e a n c o m p le te ly d e m o d e . F o r th e la s t five y e a rs , th is in d u s tr y h a s b e e n re d u c e d to a s h a d o w o f its f o r m e r self. I ts y o u n g e r c r a f ts m e n a r e n o w d is p e rs e d a m o n g s t a r m e d se rv ice s; its p la n t p u t to o th e r u s e s , a n d s o m e o f its “ s tra te g ic ” m a te ria ls in s h o r t s u p p ly o r v irtu a lly n o n -e x is te n t. W h a t is to b e its p o lic y ? I t c a n “ o b lig e ” c u s to m e rs by fu r n is h in g m a te r ia l w h ic h w ill “ g et th e m a w a y ,”

b u t th e r e b y it w ill te n d to p la c e e n a m e lle d w a re in t h a t c a te g o r y w h e re “ p re -w a r ” is th e c rite rio n o f q u a lity a sse ss m e n t. T h e y c a n re fu s e to s u p p ly u n til u n a s s a ila b le q u a lity is a s s u re d , o r a g a in th e y c a n c r e a te a c c e p ta n c e s ta n d a r d s to b e re g a rd e d as a m in im u m u n til th e f u ll re s o u rc e s o f th e in d u s tr y a re o n c e m o r e a v a ila b le . T h e C o n fe re n c e sc h e d u le d to ta k e p la c e in M a n c h e s te r in N o v e m b e r w ill giv e a n o p p o r tu n ity o f v e n tin g e x p e rt o p in io n o n w h a t is o b v io u s ly a d ifficu lt s itu a tio n . T h e fa c t t h a t “ p r e -w a r ” c a n m e a n a m u c h h ig h e r o r a m u c h lo w e r lev el o f q u a lity a n d p e r fo r m a n c e m u s t b e re a lis e d a t th is im p o r ta n t ju n c tu r e b y e v e ry b o d y w h o h a s th e w e lfa re o f h is in d u s tr y — t h a t is h is liv in g — a t h e a rt.

C ontents

“ P re-W a r ” Q u ality , 65.—Dr. H a ro ld Moore to R etire , 66.—

N o tes from th e B ranches, 66.—Specifications. Q u a lity Control an d In sp e ctio n , 67.—F ir s t R ep o rt on th e B asic Cupola by th e M eltin g F u rn ac e s Sub-Com m ittee, 71.—I n s titu te of V itreous E n am ellers, 74.—W artim e C alls on W om en to M ake A lum inium Air-Cooled C ylinder H eads. 75.—Iro n fo u n d rv Fuel N ew s—X X I I , 78.—N ews in B rief, 80— P erso n al. 80.—C om pany R esults, 82.—O b itu a ry . 82.—B la st-F u rn a c e W o rk ers’ W ar Record, 82.—R aw M ate rial M ark ets, 84.

6 6 FO UNDRY TRADE JO U R N A L SEPTEMBER 28, 1944

DR. H ARO LD MOORE TO RETIRE NOTES FROM THE BRANCHES

Dr. H aro ld M oore, C .B .E ., w ho was ap p o in te d D irecto r o f the B ritish N o n -F e rro u s M etals R esearch A ssociation in 1932, will retire fro m th a t p o st on O c to b er 31 n ex t, w hen, a t th e age o f 66, h e w ill hav e co m p leted 12 y e ars’ service to th e A sso ciatio n an d 50 years in th e stu d y an d p ractice o f m etallurgy.

As a p u p il o f th e late D r. J. E. Stead, F .R .S ., D r.

M o o re, a t th e beginning o f his m etallu rg ical career, was b ro u g h t closely in to to u c h w ith th e iro n a n d steel in d u stry o f his n ativ e to w n , M id d lesb ro u g h , a n d fo r m an y years his in terests w ere m o re fe rro u s th a n n on- ferro u s. A fte r g ra d u atin g in th e U n iv e rsity o f L o n d o n he o b tain ed in d u stria l experience in a sm a ll N o rth a m p ­ to n sh ire b last-fu rn a ce p la n t a n d th en in th e P a rk h e ad steelw orks of W illiam B eard m o re & C o m p an y ,

Lim ited.

In 1904 h e w en t to the re sea rch d e p artm e n t, W o o l­

wich, as ch ief m etallu rg ist an d , a fte r th e e x p an sio n of his scientific staff fro m fo u r to 40 d u rin g th e 1914-18 w ar, he w as desig n ated D ire cto r o f M etallu rg ical R e ­ search. As m eta llu rg ic a l ad v iser to th e W a r Office an d to th e O rd n an ce D e p a rtm e n t o f th e A d m iralty , D r. M o o re h a d m u ch experience o f Service problem s, b o th ferro u s a n d n o n -ferro u s, a n d fo r his w o rk on these he received the C.B.E. in 1932.

C o -o rd in atio n o f R e search W ork

D r. M o o re alw ays h e ld strongly th a t th e research w ork carried o u t by G o v e rn m e n t estab lish m en ts should be p art o f th e g en eral stream o f scientific progress, and h e did m u ch to p ro m o te the co -o p e ra tio n o f his d e p a rtm e n t w ith in d u strial la b o ra to rie s an d w orks, an d scientific a n d tech n ical in stitu tio n s a n d U n iversity an d o th e r research establishm ents. H e a n d his fellow w orkers a t W oolw ich p u b lish ed m an y scientific Papers.

P erh ap s th e b est k n o w n o f these, fo r w h ich D r. M o o re was him self larg ely resp o n sib le, w ere a n u m b e r o f P ap ers on “the season-cracking o f brass. H e joined, an d is still a m em b er of, th ree o f the jo in t technical com m ittees o f th e Iro n a n d Steel In stitu te a n d th e B ritish Iro n a n d S teel F e d e ra tio n , an d w as fo r a tim e c h airm a n o f th e Steel C astings R esearch C om m ittee.

H e becam e a m em b er o f C o u n cil o f th e In stitu te o f M etals a n d w as c h airm a n o f its P u b lica tio n C o m m itte e fo r six years. S uccessful re searc h on sev eral in d u s­

trial p ro b lem s carried o u t fo r th e B ritish N o n -F e rro u s M etals R esearch A sso ciatio n a t W oolw ich led to his being invited to serve as a m em b er o f th e A sso cia­

tio n ’s C o u n cil, a n d later, on D r. R. S. H u tto n ’s ele c­

tio n to th e G o ld sm ith ’s C h a ir of M etallu rg y a t C a m ­ bridge, to D r. M o o re succeeding him as D irecto r.

F ro m 1934 to 1936 D r. M o o re w as P resident o f the In stitu te o f M etals, an d h e has tak en a p ro m in e n t p a rt in its activities fo r m an y years. T h e In stitu te h as show n its a p p re c ia tio n o f this w o rk b y a w ard in g him its F ellow ship. In 1943, h e received th e In stitu te ’s P latin u m M edal, aw ard ed an n u a lly “ fo r o u tstan d in g services to n o n -ferro u s m eta llu rg y .” H e h a s re p re ­ sen ted th e In stitu te a n d also th e B ritish N o n -F e rro u s

(C o n tin u ed at fo o t o f n e x t co lu m n .)

L o n d o n B ranch, S lo u g h S ectio n .— A b o u t 40 m em ­ bers an d v isitors w ere p resen t o n S ep tem b er 14 a t th e first g en eral m eetin g , w h ich w as h e ld in th e lectu re th ea tre o f H ig h D u ly A lloys, L im ite d . M r. V. C.

F a u lk n e r (Past-.P resident o f th e In stitu te ) presided.

M r. A. L o g an w as elected c h airm a n o f th e S ection;

M r. R. B. T em p le to n a n d M r. Ia n R o ss, v ice-ch air­

m en; M r. E. Jo h n P ike, h o n o ra ry se cretary ; an d M essrs. T. F re e m a n , E. W. H a rd y , F . M cK en n in g , S. B. M ichael, E. R a y b o u ld a n d G . S kript, m em bers o f th e C ouncil.

A fte r th e business m eeting, M r. F . H . H o u lt, general m an a g er of K e n t A llo y s, L im ited , in tro d u c ed the A m erican so u n d film. “ W artim e C a lls on W om en to M ake A lu m in iu m A ir-cooled C y lin d e r H e ad s ,” in asso ­ cia tio n w ith M r. G re g o ry ’s P a p e r on th e subject. An excellent discussion en su ed a n d M r. H o u lt w as c o r­

d ially th a n k e d by M r. L o g an a n d M r. R a y b o u ld on b e h alf o f th e m em b ers. A c k n o w led g m e n t w as also m ad e to H ig h D u ty A llo y s, L im ited , fo r th e use of th e ro o m a n d to M r. F a u lk n e r fo r presiding.

S o u th A fric a n B ra n ch .— T h e a n n u a l g e n eral m eeting o f the B ra n ch w as as u su a l p re ce d ed by a festival d inner. T h is w as h e ld a t th e V ic to ria H o te l, Jo h a n n e s­

burg, on Ju n e 27, M r. J. M . S tones presiding. In his v a led icto ry ad d ress, M r. S tones re p o rte d th at the m em bership, a t 203, p laced th e B ran ch high up in the list. D u rin g th e y e a r sections h a d been fo rm ed at C ap e T o w n a n d D u rb a n . In co n n ec tio n w ith the fo rm er, h e expressed th e th a n k s o f th e C o u n c il to Mr.

Z w an zig er f o r th e p a r t h e h a d p lay ed in its creation.

A n o th e r im p o rta n t re c e n t d e v e lo p m en t w as th e o p en ­ ing o f a tec h n ica l lib ra ry b y th e B ra n ch , a n d c o -o p era ­ tio n w ith th e Jo h a n n e sb u rg P u b lic L ib ra rie s h a d been assured. H e e x p ressed th e sincere th a n k s o f the m em b e rs to M r. S k o k f o r h is e x cellen t w o rk as h o n o ra ry secretary. O n a m o tio n p ro p o se d by M r.

T onge. seconded by M r. N im n o , M r. S to n es was very c o rd ia lly th a n k e d f o r h is address.

T h e fo llo w in g officers w ere elected f o r the fo rth co m - s e s s io n :— President, M r. P. L. W ard ; vice-president, M r. H o ld sw o rth ; ho n . secretary, M r. S kok; m em bers o f council, M r. B. S tu th rid g e, C a p ta in T ic to n a n d M r.

R etief.

M r. W ard delivered a s h o rt ad d ress on the p o st-w a r p ro sp ects f o r th e S o u th A frican fo u n d ry in d u stry .

(C o n tin u e d fr o m p rev io u s co lu m n .)

M etals R esearch A sso ciatio n on the executive o f the P arlia m en tary an d Scientific C o m m ittee.

D r. M o o re h as f o r som e y ears been c h a irm a n of the N o n -F e rro u s In d u stry C o m m ittee o f the B ritish S tan d ard s In stitu tio n , a n d has served on large n u m ­ bers o f its tec h n ical com m ittees. H e is, fo r th e second tim e, a m em b e r o f th e C o u n c il o f the R ov.il In stitu te o f C hem istry,

SEPTEMBER 28, 1944 FOUNDRY TRADE JOURNAL 67

SPECIFICATIONS, Q U ALITY C O N TR O L ^ r- J: F: 1K,°Lsers

A K I r"N iK I c* 1“ ✓"*"!" I f \ K I i f £ S ÍdGfl t í 0 1 A d dT6SS

A N D INSPECTION

F o u n d ry m en o p en ed its 1944-45 session w ith a m eet­

ing at the W ald o rf H otel, A ldw ych, W .C.2, on A ugust 31, at w hich, in spite of flying-bom b a ttack s on the M etropolis, th ere was a go o d a tten d an ce o f m em bers to w itness the in au g u ra tio n of their new P resident, M r.

J. F . K ayser, a n d to w ish him well d uring th e com ing session. M r. K ay ser delivered his Presid en tial Address.

M r. R. B. T em p leto n (Past B ra n ch P resident) p re ­ sided d u rin g the early p a rt o f the m eeting, in the absence o f the retiring president, M r. H. W. L ockw ood.

A pologies fo r absence w ere received fro m M r.

L ockw ood a n d M r. G . R. W ebster.

In d u ctio n o f B ranch P resid en t

W elcom ing M r. K ay ser as B ranch President, and in­

viting him to occupy the chair, M r. T em p leto n said that all w ho h a d a tte n d ed th e B ra n ch m eetings h a d been im pressed by M r. K a y se r’s refreshing o u tlo o k on Papers th a t w ere p resented. H is criticism s h ad alw ays been kindly and. th ough fairly severe, had alw ays been con stru ctiv e; he possessed a m ind o f a type w hich was an in v alu ab le asset in discussion. He was n o t co m p la ce n t; he h a d a sp irit o f “ divine dis­

content,” an d w ould n o t accep t everything th a t was said w ith o u t expressing som e little d o u b t. In c o n te m ­ plating M r. K ay ser’s elevation to the Presidency o f the Branch one felt ra th e r as law yers m ight feel w hen a brilliant K .C . w as elev ated to a Jud g esh ip ; th a t w hich was lo st in discussion w ou ld be com pensated by the exercise of his abilities judicially w hile he occupied the P residential C h air. O ne co u ld th in k o f no m ore fit­

ting clim ax th an th a t M r. K ayser, having delivered his Presidential A ddress, sh o u ld re tu rn tem p o rarily to the body o f the h a ll a n d criticise it!

On b e h alf o f the B ranch, M r. T em p leto n w ished M r.

K ayser every success an d happiness d uring his period of office.

P resid en tial A ddress

Mr. Ka y s e r, h aving fo rm ally occupied th e chair, amid ap p lau se, p resen ted his P re sid e n tial A ddress, in w hich h e s a id :

M r. T em p leto n a n d G en tle m en ,— I c a n n o t tell yo u how pleased I am to be elected P resid en t o f the London B ranch. It is an h o n o u r w hich I value ju st as much as I value the d ip lo m a w hich you gave me m any years ago fo r a P a p e r w hich I had read. T h is is the first occasion on w hich I have been elected P resid en t of anything; p erh ap s you are the only people w ho care to risk it!

G e n e r a l l y s p e a k i n g , 1 a m v e r y d i s a p p o i n t e d in t h e f o u n d r y i n d u s t r y n o w a d a y s . 1 a m e n g a g e d m a i n l y in e n g i n e e r i n g w o r k , a n d i t g r ie v e s m e t h a t s o m a n y p a r t s a r e b e in g m a d e f r o m d r o p f o r g i n g s , o r e v e n m a c h i n e d f r o m t h e s o lid , w h e r e a s t h e y c o u l d b e m a d e in t h e

fo rm of castings. V ery often I suggest th a t a certain p a rt sh o u ld be m ade as a casting, b u t u sually m y sug­

gestion is tu rn ed dow n; then along com es a story, p ro b a b ly grossly exaggerated w ith the passing o f the years, concerning w h at h ap p en ed in co nnection with a casting w hich was m ad e long, long ago. B u t I agree th at th ere a re still m an y b a d castings m ade to-day, and I th in k it is possible to m ake som e advancem ent.

T h ere is an old L atin p ro v e rb o r m o tto , “ Q ui non profecit, defecit,” w hich, being tran slated , m eans

“ W ho does n o t advance, goes b a ck .” I do th in k th at th a t is p articu la rly ap p licab le to the fo u n d ry industry.

T h erefo re, I will discuss briefly th ree of the fo u n d a ­ tio n stones on w hich success can be built. I am not fo r a m o m en t suggesting th a t th ere are only three. 1 do n o t like to h e ar people talking o f th eir pet hobby as if it w ere the o nly h o b b y in the world.

T h ere are m an y fo u n d atio n stones on w hich are based the success o f any business. T he th ree with w hich I shall deal, in re latio n to the fo u n d ry , are specifications, q u ality c o n tro l and inspection. A ll th ree are very closely related.

Specifications

O ne o f the so u n d est sentences 1 have ever read with reg ard to specifications was published recently in

“ T h e E n g in eer,” a n d was w ritten by M r. H a rry Brear- ley. H e w ro te : “ Specifications are often c o m p ro ­ mises betw een com peting com m ercial interests m ixed w ith to ugh prejudice fro m a bygone generation and d e co rated w ith o n e o r m ore of the fashions in p reten ­ tious learn in g .”

W hen reading som e specifications, one can n o t de­

cide w h at they a re all a b o u t an d to whSrn they are addressed. Som e clauses seem to be addressed to the cu sto m er o r u ser o f the p roduct, others to the m an u factu rers, and others seem to sav o u r som ew hat o f w orking instructions. I think a specification should be a p erfectly straig h tfo rw ard docum ent, telling the m an u fa ctu re r w h at the custom er w ants; or, a lte rn a ­ tively, if the m an u fa ctu re r states th a t he can supply a p ro d u c t to specification X Y Z , th en the cu sto m er should k now exactly w hat he is buying. I do n o t th in k th at a specification sh o u ld do an y m o re o r an y less th an that.

In p articu lar, 1 do n o t th in k th a t a specification sh o u ld consist o f w orking instructions; th a t is qu ite a different m atter. T h ere m ust be w orking instructions, of course, b u t I do n o t th in k they are connected "in any w ay with the specification. A specification should indicate m erely the p ro d u ct th a t is being produced.

If I am selling anything, I state w h at I have fo r sale, an d th at is m y specification. Som etim es it is the easiest thing in the w orld to say directly w hat is w anted.

FO U N DR Y TRADE JO U R N AL SEPTEMBER 28, 1944 London B ra n c h M e e t i n g

C o n sid er a ch ildishly sim ple exam ple. S uppose we w an t to m ak e u p a special allo y a n d w ish to ad d nickel in th e fo rm o f a ferro -n ick el. T h ere w e sh o u ld have a really d irect specification. T h e cu sto m er w ould specify a n allo y co n tain in g , say, 20 p e r cent.

( + 2 p e r cent.) of nickel, the b ala n c e to be iro n , im ­ pu rities n o t to exceed, say, 11 p er cent. S uch a speci­

fication w ou ld be very n e arly a w o rk in g in stru ctio n , b u t n o t quite. C o n sid er a n o th e r very sim ple exam ple.

Suppose I w an t to b u y som e ro u n d cast-iro n ro d s of, say, 1-in. dia. I do n o t care w h a t th ey a re m ad e of.

A gain I hav e a d irect specification, statin g th a t th e d iam eter m u st be 1 in. ( + 0 . 1 in.). T h a t also w ou ld be a w o rking instruction.

B u t th ere are cases v ery m u ch m o re difficult th a n that. S uppose I hav e a c o m p licated m ach in e, such as an in te rn al co m b u stio n engine, a n d I h av e a new so rt of pisto n w ork in g a t a new speed o r w ith a new fuel.

W h at m u st I d o ? F irst, I can call o n p a st experience, w hich w ill lead m e to th in k th a t th e cy lin d er sh o u ld be m ad e in cast iro n , b y a n d large. T h e n I sh all m ake u p a n u m b er o f different cylinders a n d ring the changes on th e cast iro n ; a n d u ltim ate ly I m a y c o n ­ clude th a t cast iro n A is th e best a n d is th e one th a t I w ant. If I try to b e a re ally clever guy, o f course, I can specify “ cast iro n su itab le fo r the m a n u fa ctu re o f this cy lin d er b lo ck ,” w hich m u st hav e a life o f 10 years a t 10,000 r.p.m ., o r som eth in g o f th a t sort. But it w ould be necessary to give an in d irect specification.

I sh o u ld w an t to give th e analysis; a n d p ro b a b ly I sh o u ld tag o n a tensile, p erh ap s a n Izod a n d a V ickers d iam o n d h ard n ess, a B rinell an d , if y o u like, a fatigue.

People hav e a ten d en cy ju st to tag on things.

If I am lucky, it m ay be th at, because o f th a t c o l­

lection o f co n stan ts a n d p h y sic al p ro p erties, th e thing can be c o n tro lled so th a t I can avail m yself o f the pecu liar phy sical p ro p e rty th a t I w an t, su ch as n o n ­ d isto rtio n a t th e tem p e ra tu re w hich is a tta in e d in the engine, o r can achieve th e p ro p e r actio n or reactio n betw een th e pisto n a n d th e cylinder w alls. It seem s to m e th a t, w hen an in d irect specification such as th a t is used, the su p p lier m ust ju st keep to it.

M ode o f M a n u fac tu re and A nalysis B ut th ere are o th e r kinds of specifications w here I sh o u ld object to the inclusion of a n y th in g o th e r th an the req u irem en ts. Suppose I w a n t a p a rt th a t h as to be stressed. I th in k it sh o u ld b e sufficient to calc u ­ late the stresses a n d th en to state th a t th e m ate ria l m u st hav e certain physical properties, w hich can be given; I sh o u ld state a com pression, a tensile, e lo n ­ g atio n , Y o u n g ’s m o d u lu s— ju st w h a t I w ant. T h e specification sh o u ld c o n ta in o nly th a t, a n d sh o u ld m ak e no referen ce a t all to m ode o f m a n u fa c tu re o r to analysis.

F ro m tim e to tim e I d raw up specifications on th o se lines, a n d th e m an u fa ctu re rs m ig h t ask m e a b o u t the analysis. B ut I tell them th a t I m ust leave it to them .

O f course, if a m a n u fa c tu re r is n o t really skilled in his a r t a n d does n o t k n o w h o w to a ch iev e th e resu lts I re q u ire, a n d if I ha v e to give th e w o rk to su c h a m a n u fa c tu re r, I m ay tell h im th a t, in o rd e r to achieve the phy sical p ro p e rties req u ire d , th e m a te ria l w ill have to be m ad e in a certain w ay an d m u st b e c a s t u n d e r certain c o n d itio n s. B ut th a t m ea n s en cro a ch in g u p o n the m a n u fa c tu re r's p rero g ativ e. W h en I w as in the steel tra d e an d cu sto m ers trie d to sug g est h o w we sh o u ld achieve w h a t th ey w a n te d a n d w h en they tried to b in d us to the m eth o d s th e y suggested, we d id n ot like it a t all. S om etim es w e re ac h ed th e rid i­

cu lo u s stage a t w hich tw o p a rts o f a specification w ere a b so lu tely in co m p a tib le. T h e re w ere som e m atters w hich d id n o t c o n ce rn th e fo u n d ry directly, a n d if the in stru ctio n s on h e a t-tre a tm e n t w ere fo l­

low ed, the physical p ro p e rties re q u ire d w o u ld n o t be achieved. T h a t is m o re th a n aw k w ard .

N o w let us co n sid er th e m a n u fa c tu re r w ho has acc ep ted an o rd e r f o r so m eth in g . C o n sid e r first the very sim ple case o f the n ick e l-iro n allo y I ha v e m en­

tioned. T h ere th e sp ecificatio n is to all in ten ts and p u rp o ses a w o rk in g in stru ctio n ; it is th e targ e t at w hich the m a n u fa c tu re r m u st sh o o t, a n d he w ill know w h eth er o r n o t he h as h it it. H a s he g o t 20 p e r cent, nickel (w ithin th e lim it o f + 2 p e r cent.), a n d h a s he confined th e im p u rities to w ith in the to p lim it o f 1+

per cen t.? T h a t is a v ery sim p le case. I f y o u w ant castings yo u m ay co n sid er m ere ly a n in d ire ct specifica­

tion, such as a sta te m e n t o f p h ysical p ro p erties, but it is o f no use tellin g th e s te e lfo u n d e r th a t yo u w ant steel castings o f 45 to 55 to n s per sq. in. tensile; that w ould n o t be a d irec t targ e t f o r th e ste elm ak er and the m ak e r o f th e castings. Y o u m u st specify things so th a t th ey p ro v id e a d irec t aim .

F irst y ou m u st decide on th e m etal, a n d m u st en ­ su re th a t th e fo u n d e r alw ay s h a s th e sam e ta rg e t in fro n t o f him . It is fo r th e p e rso n resp o n sib le for tu rn in g o u t the m etal to see th a t h e h its as n e arly as possible th e cen tre o f th a t targ e t, w hich m ay be even a series o f targ ets if th ere are different con stitu en ts to co n tro l.

Control

F u rth e r, ev ery th in g else m u st be c o n tro lled . T here m u st be co n tro l o f the sand a n d o f the w ay the m ould is m ad e — n o t m erely a s tip u la tio n as to w h ere the ru n n e rs a n d risers go. T h e q u estio n arises as to how and w hen are y o u going to co n tro l th e v a rio u s fa c ­ tors. F o r m an y y ears I have b een so m ixed u p with m ass-p ro d u ctio n th a t it is b o u n d to influence my m ind. W h en one is tu rn in g things o u t in co u n tless th o u sa n d s every day, one th in k s o f e v ery th in g else being tu rn ed o ut in co u n tless th o u san d s. I w a n t you to visualise th a t it is a fo u n d ry p ro p o sitio n to tu rn things o u t in th o u sa n d s every d ay an d every m o n th th ro u g h o u t the y ear. T h ere is no re aso n a t all m echanically, a n d even p erh ap s m etallu rg ically w hy yo u sh o u ld n o t hav e san d bins, m elting fu rn ac e s an d m o u ld in g m achines in a line, so th a t th e sand c an be fed dow n shutes an d p ut in to the m o u ld s, the m etal p o u red at th e p ro p e r tim e, an d the boxes being sh ak en

SEPTEMBER 28. 1944 FOUNDRY TRADE JO U R N AL 69 out a t the o th e r en d o f the line. Y o u can do things

like th a t m ech an ically .

But the g re at th in g a b o u t m ass-p ro d u ctio n is th a t you m ust decide w h ere an d w hen yo u are going to break the c irc u it fo r ex am in a tio n purposes, fo r c o n ­ trol of q u a lity a n d fo r tak in g o u t th e p a rts th a t are bad; defective w o rk m an sh ip alw ays arises. Som etim es it will be n ecessary to h av e a n o p e ratio n co n tro lled all by itself an d th e re m u st be a co m p lete sto p fo r purposes o f e x am in atio n b e fo re the w o rk goes on.

1 am a fra id th a t in the fo u n d ry it w ou ld be necessary to break in very m an y differen t places if y ou are to ensure tu rn in g o u t a go o d p ro d u ct. It is a q u estion as to w here in sp ectio n sta rts a n d w here q u a lity co n ­ trol starts in the fo u n d ry .

I am n o t co nsidering q u a lity c o n tro l m erely by th e use of statistical m eth o d s, a b o u t w hich o n e reads so much now adays. Q u ality co n tro l by th o se m eth o d s may have its uses; b u t I th in k it is a passing fancy, and I hav e n o t a rriv ed a t th a t co n clu sio n rashly.

Since I first re a d a b o u t it, som e th ree o r fo u r years ago, I have studied it m o st deeply a n d h av e gone into the th eo ry o f statistics. W h ilst I do n o t q u a rre l, I do not th in k th a t its a p p lic atio n , as offered by som e people, is th e rig h t one. T h ere is a very g reat d eal to be learn ed fro m statistics; a n d I do th in k th a t every foundry, h o w ev er sm all, if it has an y co n tro l a t all.

should p resen t its results u p o n w h at one m ight call a statistical basis.

T h e F re q u e n c y D ia g ra m

My fa v o u rite basis, w hich I th in k is a p p licab le to practically everything, is the freq u en c y diag ram . It can be a p p lied rig h t th e w ay th ro u g h — to the m o iste n ­ ing of th e sand, th e p ercen tag e o f w asters, an d every­

thing else. Y o u can re ally p resen t results usefu lly in the fo rm o f a freq u en cy diagram . I t is so c le ar th a t you can show it to a c o m p a rativ ely u n tu to re d w o rk ­ man w ho, th o u g h h e m ay n o t fo llo w exactly w h a t it is all a b o u t, w ill a p p reciate th e p o in t yo u are m aking.

You can show him th a t the p oints w hich in d icate re ­ sults are extending o v er one or o th e r o f tw o red lines, whereas th e y sh o u ld be in the centre. F ro m e x p eri­

ence I have fo u n d th a t if y o u talk like th a t to a m an, he will a p p reciate th a t the p o in ts should be in the centre, fo r e v ery b o d y has the idea th a t if yo u have a target, y o u sh o u ld h it it in th e m iddle.

F req u en cy d iagram s are p u b lish ed in the e n g in eer­

ing an d m etallu rg ical jo u rn als. G e n e ra lly speaking, a frequency d iag ram , w h eth er it relates to the m oisture content o r clay c o n te n t o f the sand, o r to any th in g else, sh o u ld be sy m m etrical a n d sh o u ld have a certain slim shape. T h e m an a g er o f a very com plicated organisation can hav e freq u e n cy d iagram s placed b e ­ fore him every d a y an d w ill b e ab le to see a t a glance w hether o r n o t th e v ario u s aspects o f the w ork are proceeding as th ey sh o u ld . E ven w ith o u t know ing w hether a p a rticu la r d iag ram deals' w ith tensile results or c arb o n c o n te n t or an y th in g else, he w ou ld kn o w at once w h e th er o r n o t things w ere going right, fo r, if there w ere an y th in g w rong, he w ould notice it a t once by reason of th e shape o f the diagram . U n ­

less th ere is som ething w rong, th ere is no need to b o th er a t all. T h a t is a n exceedingly useful a p p lic a ­ tion o f statistical m ethods.

In sp ectio n

W ith re g ard to inspection, I sh o u ld like to see a greater tendency to inspect m oulds. W hen I am p u r­

chasing castings, I alw ays ask if I m ay look a t the m oulds; b u t very few people do th a t, a lth o u g h th ere are exceptions. Surely, having inspected th e sand, as yo u sh o u ld do in o rd e r to ensure th a t it is o f the right so rt an d is p ro p erly m illed an d m ixed, yo u should also inspect the m ould.

I h a d a very severe train in g in th a t connection.

B efore I h a d h a d any experience a t all I was ap p o in ted m an a g er o f a sm all fo u n d ry — indeed, I h a d to start it off— a n d d id n o t know th a t th ere w as such a thing as a fettlin g shop. C on seq u en tly , I set o u t to m ak e castings, w ith the assistance o f o n e o r tw o very en ­ thusiastic m oulders, a n d we h a d no fettlin g d e p a rt­

m ent; so th at, if a n y th in g w en t w ro n g w ith a casting, there was no hope fo r us. W e h ad to av o id scabs and we h a d no m eans of w elding in a chip, so th a t we h a d to get things right in the foundry. I think th a t if som e fo u n d ries h ad to do w ith o u t th eir fettling shops th eir castings w ould be very m uch b etter; th ere are so m an y people w ho rely on others to p u t right th eir failures. T h a t hap p en s in engineering, an d the last m an in the chain, w ho has to assem ble an engine or som e o th e r a p p ara tu s, has to “ carry th e b a b y .”

In m a n y w ays th e fettling shop h as to “ carry the b a b y ” fo r th e fo u n d ry , a n d th a t is w rong. N o t long ago I saw a m a n in a fettling sh o p drive a chunk of steel in to a h o le in a casting a n d weld over it. T h a t did n o t create a goo d im pression in m y m ind. If th ere h a d been no fettlin g shop, th a t casting w ould never have le ft th e fo u n d ry ; the m ak er w ou ld h av e know n th a t it was “ his b a b y .”

T h a t is one reaso n w hy you sh o u ld inspect m oulds.

I do n o t suggest th a t if you a re m ak in g a stern post, fo r exam ple, you should b reak u p the m ould fo r in ­ spection; b u t fo r o rd in ary p roducts yo u should in­

spect th e m oulds, just as yo u inspect a finished cast­

ing. I w ou ld n o t have a patch ed -u p m ould. P u ll one to pieces to ensure th a t it is u n ifo rm ly ram m ed. T hen, when th e boxes are being closed, I w ou ld certainly op en one in o rd e r to see w h at it lo o k s like. T h a t is w here inspection should start, an d it should continue th ro u g h o u t.

A re w e to rely on statistical m ethods in exam ining the castings them selves? It m eans th at we are going to judge the q u ality o f a very large n u m b er o f castings by a few sam ples, n o t by inspecting a sam ple here and th ere a fte r all the castings have been m ade, b u t by tak in g a n u m b er of sam ples in the course o f p ro ­ duction. It can be done w ithin lim its, b u t th a t is n o t 100 p er cent, inspection. If y o u w an t 100 per cent, inspection, to be a b so lu te ly certain th a t a ll y o u r castings a re sound— I do n ot th in k it is possible ex­

cep t in the m o st special cases— yo u m u st X -ra y them . It is suggested in co n n ectio n w ith X -rays th a t you can inspect by screening. If the defects are so b ad