Readers' Views and Comments Flakes in Nickel Steel Gun Forgings To the Editor of Chemical & Metallurgical Engineering SIR: In the Rochester district during the past two years the Ordnance Inspection Office had considerable trouble with flakes in gun forgings made in that region. Recently we reviewed all reports of physical tests on guns and classified the data contained. The results are especially interesting in that they compile the tests on approximately 4000 gun forgings in this summary. Chart No. 1 shows that in forgings made from ingots cast during the months of January, February and March, 1918, over 50 per cent contained flakes. The percentage of flakes decreased continually after Feb 60 50 February and March, 1918, contained 3 to 3.5 per cent nickel. After that time the percentage of Ni was decreased until the forging ingots cast in September, October and November, 1918, were made of either straight carbon steel or steel containing 1 per cent of nickel. A great deal more care was also taken in casting and forging as the seriousness of this flaw was realized. Dr. H. M. Howe's theory of cracks forming either when the ingot is cooling or when it is forged seems very logical to me. The physical results obtained from test bars seemed the only argument against it. To settle this point in my own mind, I carefully measured the area of several flakes in different bars and subtracted Physical Properties Full Area Minus Area of Flake Per Cent." "Flaky" Ultimate El. Limit this area from the original area of the bar. The figure thus obtained was the actual area of sound metal. I then divided this area into the load at elastic limit and tensile strength. It is to be noted that the tensile strength obtained in this way is not unreasonable in any case. Table I gives the figures for several bars. I feel that this trouble was due entirely to forced production and that it will disappear entirely now that the need of steel is not so great and more care can be taken in making the steel correctly. Flakes tended to form by heats. However, this was not always the case. Results indicate that the tenderness of the steel is dependent on the conditions under which the steel is made and thus varies from different heats. District Metallurgist, Rochester Ordnance Office, RALPH A. HAYWARD. Electric Brass Melting To the Editor of Chemical & Metallurgical Engineering SIR: May I direct your attention to an error appearing in your issue for July 1, 1919, page 9, wherein you give the power cost for an electric furnace as 0.86 cent per kilowatt-hour. This figure would be correct if all of the 70,000 kw.-hr. used per month was charged to the electric furnaces; but as a matter of fact 20,000 kw.-hr. was used for lights or motors, leaving only 50,000 used directly by the furnace. Accordingly, the equation at the bottom of page 9 should be 602.5 ÷ 50,000 1.205; also the first line on the top of page 10 should read "The electric furnace cost is 1.205 cents per kw.-hr., and in Table II. p. 10, the power price for the first case is 1.205 cents instead of 0.860. Western Chemical and Metallurgical cost material. Argenteuil County, Quebec, has notable Field Low-Temperature Distillation PROCESS for low-temperature carbonization which bia has been experimented with at Nanaimo under the auspices of the inventor, Walter Thomas, and a Vancouver firm, McPherson & Fullerton Bros. Originally it was tried on Nicola Valley coal; the products were a semi-coked smokeless fuel, and about 7 gal. of oil per ton of fuel, with little permanent gas. Later work has produced a good dense charcoal from mill waste obtainable for a few cents per cord. In operation, a vertical brick-lined retort some 14 ft. high and 3 ft. in diameter is filled with coarse material to be carbonized, then closed, and the air contained in the system forced by a fan through a pipe stove and into the top of the retort. This passes down through the mass to be carbonized, thence through a pipe condenser and an electrical precipitator to remove liquid hydrocarbons, and back to the fan for recirculation. As the carbonized fuel becomes hotter, gases will be given off so that after a time rich distillation gas should constitute the circulating medium. Dr. Stansfield in his recent report on Electric Smelting of Iron Ore in British Columbia presents a short note on this process. He sees many drawbacks to the scheme as it was illustrated to him, such as the difficulty of forcing gas through the field retort, the slow heating of the carbonizing mass by the circulating gases, which are of low temperature and low heat capacity, the inefficiency and expense of the ordinary pipe stove, and the decomposition of hydrocarbon which will take place at this point. He has been assured, however, that enough work has been done to convince the backers of the process that they can make satisfactory charcoal at a cost of about $5 per ton, in a cycle of operations lasting six hours. Magnesite for Flooring Composition Magnesite trade has been generally very quiet since. the signing of the armistice, marking time with the steel industry, the principal consumer. Refractory manufacturers absorb perhaps 85 per cent of the magnesite output in making brick and granular material for steel and copper furnaces, while the balance is used chiefly for flooring. For the latter, both caustic magnesite (carbonate burned down to 2 to 4 per cent CO) and a German magnesium chloride were used before the war. Recently, however, a scarcity of materials has raised the price of high-grade floor compositions to a point where their use is almost prohibitive. The principal manufacturers of composition flooring have lately organized and instituted a co-operative research at the Pittsburgh laboratory of the Bureau of Standards to determine proper specifications for raw materials, calcination and method of laying the floor. It is hoped that the price can be brought into competition with that of hardwood flooring, when large quantities of it should be used. As is well known, the principal American deposit is in Washington, where large-scale production is possible under most favorable manufacturing conditions. California deposits are more scattered and not well developed, and will consequently produce but little low magnesite resources, having shipped 16,700 tons crude ore, and 22,700 tons of calcined material during 1918, of which 80 per cent was exported, mostly to the United States. Iron and Steel in Canada in 1918 Canada produced 1,163,520 short tons of pig iron in 1918 from blast-furnaces, including those of the Dominion Iron & Steel Co., at Sydney, N. S.; the Nova Scotia Steel & Coal Co., at North Sydney, N. S.; the Standard Iron Co., at Deseronto, Ont.; the Steel Company of Canada, at Hamilton, Ont.; the Canadian Furnace Co., at Port Colborne, Ont., the Algoma Steel Corp., Ltd., at Sault Ste. Marie, Ont., and the Midland Iron & Steel Co., at Midland, Ont. This production was slightly less than in the two years preceding, but it was augmented by 30,425 tons of electric pig from steel scrap. mostly low-phosphorus pig from shell turnings. electric furnaces were operated at Hull and Shawinigan Falls, Que., at Orilla, Collingwood, St. Catherines, Toronto, Belleville, and Bowmanville, Ont., and at Port Moody, B. C. Ferros, chiefly ferrosilicon and a little ferromolybdenum and ferrophosphorus were made in electric furnaces to the extent of 44,700 tons, valued at $4,730,000, over half of which was exported. Practically all the pig iron was consumed in Canada, however, the amount being slightly increased by a net import of about 65,000 tons. Such Steel ingots and direct steel castings amounted to 1,893,000 short tons, of which 73,000 tons were of the latter category. Both of these classifications show a considerable increase over the figures for 1917. Electric steel amounted to 120,000 tons, as compared with 50,000 in 1917 and 61 in 1914. Some 220,000 tons of steel products (exclusive of shell) were exported. Thus Canada is practically self-contained as to iron and steel products of ordinary use. Electrometallurgical Research Laboratory in A laboratory designed to investigate problems arising in the electric smelting of various kinds of nonferrous ores has been added to the laboratories of the Beckman & Linden Engineering Corporation at San Francisco, and is now working on a nickel-copper ore which apparently will give a metal of similar character to monel metal. In view of the variety of mineral resources of the West Coast and the large amounts of hydro-electric power which will be available in years to come, the laboratory should prove to be of great help in promoting electrothermic reduction of ores in that region. The equipment consists of complete electrical appliances to give 100-kw. single-phase current at a voltage range of from 40 to 120, together with proper switchboard and portable instruments for studying the electrical and temperature conditions during operation of a furnace. Semi-permanent furnaces will be erected as required by the study in hand, as is usual in research laboratories of this sort, an ample supply of leads, electrodes, refractories, ladles, molds, sampling equipment, and so on, being held in stock. In addition to this equipment, the laboratory is equipped with a 15-kw. low-voltage motor generator set, with the necessary accessories for studying problems in electrolytic decomposition and deposition. Tapping-Floor Ventilators "Safety-first" movements are responsible for the almost universal installation of ventilating hoods over forehearths and ladles around lead furnaces, for removing smoke perhaps more annoying than dangerous except at the lead well. Some of the installations work but passably, and tempt the furnaceman to neglect them, since they remove so little smoke as to be worth little trouble. He feels that he should not be asked to do anything except keep the lower part of the furnace in operating order, and such extra frills must be practically foolproof and automatic if they are to remain in operation. Even in the best installations which keep the tapping floor practically free from smoke, it is almost impossible to get workmen to close a damper in the matte-pan hood during the time it is not needed and thus save draft; if, on the other hand, stoppage of the fan throws the entire system out of order, they pour out of the building and vociferously demand more speed in repairing a condition they would have accepted as part of the job ten years ago. Herewith are sketched some ideas observed in a successful hood system at a furnace using two forehearths in series. Since these crust over with chilled slag soon after being replaced, it is only necessary to hood the spouts and a small area where the slag enters. Furnacemen will keep these hoods somewhat high so that the outer air drawn in around the cages will not burn too quickly the wood placed on the spouts to keep them open, so extra clearance should be allowed at these places. One side of the hood at the furnace should also be cut back as shown, so that the tap-hole may be opened and closed without continual adjustment. A complete system will involve hoods closely covering the lead pot, the matte pan and the slag pot, as well as two for the spouts to settlers No. 1 and No. 2. Each is closely counterweighted so it can be easily raised out of the way, by a rugged mechanism somewhat like that indicated, the lower pipe, smooth outside, telescoping into the upper part through a flap of conveyor belting, simple stops limiting the travel. Shaft A, for instance, is extended a sufficient distance to carry a guarded sprocket so that a loop of light chain can hang down to a handy point on the floor, easily reached and yet not interfering with ordinary furnace work. A like arrangement actuates a butterfly valve in each pipe, its position, whether open or shut, being shown by an arrow at the side of the pipe. Exhaustion is effected by a fan capable of handling 6000 cu.ft. per min. per furnace; a draft of about 1 in. at the fan will usually be sufficient. The very dilute smoke is discharged into the main blast-furnace flue, and the values recovered. As noted before, the fume rising from the lead pot is dangerous, the dense sulphur fumes from the matte pan quite irritating, while the mixed smoke from a slag stream is disagreeable from its volume and heat. Exposition Plans and Exhibitors THE HE Fifth National Exposition of Chemical Industries, which will be held in Chicago during the week of Sept. 22, promises to be of exceptional interest, since many of the inventions and developments made under the stress of war-time necessity will be shown publicly for the first time. As instances, we may mention: acid and alkali proof bronzes, prepared for specific purposes that even quite recently were unheard of; bronze of such hardness and strength that instruments made of it are used to cut chilled steel; technical organic products developed for waterproofing and fireproofing; instruments perfected during the war for precise measurements of temperatures, weights, volumes, velocities, flow of liquids, gases, electric currents, etc. A feature of the exposition will be the exhibits of electric furnaces, which will include the Rennerfelt furnace, handled in America by Hamilton & Hansell; the Bailey furnace, by the Electric Furnace Co.; the Taylor furnace, by the Industrial Electric Furnace Co.; the Detroit Rocking furnace, by the Detroit Electric Furnace Co., the furnace of the Booth-Hall Co., and many others. The Bureau of Mines will show the complete course of extraction of some thirty metals from their ores, together with the materials used in the extraction. In addition, the Bureau will have a collection of protective and safety devices, such as goggles, shields, masks, hoods, oxygen helmets, etc., and will hold a symposium upon "Safety in the Plant and Mine," with speakers of authority in this work, under the chairmanship of M. L. Leopold, safety engineer of the U. S. Bureau of Mines. In the evening after this meeting, which will occupy an entire afternoon, there will be shown a series of motion pictures of safety work in plant, field and mine-pictures now being made in industrial plants all over the country under the supervision of Government agents. The Forest Products Laboratory of the Forest Service will make an exhibit of the work it has been conducting on processes, raw material, products, by-products, etc. Among the subjects will be the investigation on pulp and paper, ethyl alcohol from wood waste and sulphite liquor, the increased production of acetate of lime in hardwood distillation, and the naval stores investigations. The Technical Association of Pulp and Paper Industry is planning an exhibit showing all the phases and stages in paper making from the tree to the finished paper, including illustrations of the machinery through which pulp passes in all stages. The Bray Studios will endeavor to show, by means of animated drawings, the mechanism of certain chemical actions usually invisible to the eye and only conceived by the mind in abstract form. The following partial list of exhibitors indicates clearly the scope of the Exposition: Abbe, Paul O. Abbe Engineering Co. Abbott Laboratories Ainsworth, Wm., & Sons Allen Electrolytic Cell Corp. American Flectrochemical Society American I a France Fire Engine Co. Gaertner, W., & Co. General American Tank Car Corp. General Ceramics Co. General Chemical Co. General Fire Extinguisher Co Groch Centrifugal Flotation Co. Gruendler Patent Crusher & Pulv, Co. Hamilton & Hansell, Inc. Hercules Engineering Corp. Huff Electrostatic Separator Co. Industrial Electric Furnace Co. Sarco Co., Inc. Sargent, E. H., & Co. Schaeffer & Budenberg Mfg. Co. Scientific Materials Co. Shawiningan Electro Metals Co. Valley Iron Works Co., Van Schaack Bros. Chem. Works Vitreous Enameling Co. Wallace & Tiernan Co., Inc. Wedge Mechanical Furnace Co. Werner & Pfleiderer Co. Zapon Leather Cloth Co. Status of the Domestic Magnesite T A tariff hearing before the House Ways and ATA tariff before to and 17, 1919, it was testified that before the war 95 per cent of the magnesite consumed in this country was imported from Austria and that since then most of it has been produced from mines located in California and in Washington State. In 1914 the cost of imported dead-burned magnesite at Atlantic ports was between $16 and $17 a short ton, and the brick made from this material sold for $112 a thousand, 9-in. standard basis. The cost of deadburned domestic magnesite, at the time of the hearing, at Atlantic ports was $49.10, and brick made from this material was bought for $400 a thousand. As much as $600 a thousand was paid during the war. The amounts imported are shown in Table I and the domestic production in Table II. The domestic magnesite is procured from deposits in California, where it occurs in an amorphous form in veins of varying size, and from deposits in Washington State, where it occurs in a crystalline form in large massive deposits similar to limestone. The development of the California deposits is shown in Table III. The Washington deposits were not developed until 1917. During the year 1918 two companies produced 105,175 short tons crude magnesite from the deposits located at Chewelah and Valley. The known reserves in this country are 8,000,000 tons, the deposits of southern Europe are estimated to contain between 120,000,000 and 130,000,000 tons. The request of the producers for a protective tariff is incorporated in bill H. R. 5218 as follows: A BILL To provide revenue for the Government and to establish and maintain the production of magnesite and manufactures thereof in the United States. Be it enacted by the Senate and House of Representatives of the United States of America in Congress assembled, That on and after the day following the passage of this act, there shall be levied, collected and paid upon the articles named herein, when imported from any foreign country into the United States or into any of its possessions, the rates of duties which are herein prescribed, namely: 1. Magnesite, commercial ore, either crushed ground, three-fourths of a cent per pound. or 2. Magnesite, calcined, dead burned and grain, 11 cents per pound. 3. Magnesite brick, 25 per centum ad valorem. SEC. 2. That paragraph 539 of the tariff act of Oct. 3, 1913, is hereby expressly repealed; and that so much of paragraph 71 of said tariff act and of any heretofore existing law or parts of law as may be inconsistent with this act are hereby repealed. The testimony of the witnesses at the hearing is conflicting; consumers of brick made from domestic magnesite claimed it to be inferior to brick made from Austrian magnesite, the life of the domestic product being between 60 and 80 per cent of the foreign. H. F. Wierum, general manager of the American Mineral Production Co., at Valley, Wash., claimed that brick made from a dead-burned magnesite produced at his plant was equal to brick made from Austrian magnesite. March this year, and brick made from this product has been as satisfactory as those made from Austrian magnesite. This plant seems to be the only one that has made an intelligent effort to produce a dead-burned magnesite which will produce a satisfactory brick, and it is probable that co-operation between the producer of dead-burned magnesite and the manufacturers of brick will lead to more satisfactory results. Ways and Means Committee Acts on Tariff Bills THE HERE is a safe majority among the members of the Committee on Ways and Means of the House of Representatives opposed to the licensing system. This fact developed at the first meeting of the committee to consider the evidence submitted at the hearings which had been conducted on various commodities which were most in need of safeguarding. The opposition to the licensing system does not extend to that suggested for the dyestuff industry, in which it is practically certain that a licensing plan must supplement the duty. At its meeting, the committee reported favorably, without amendment, the bill introduced by Representative Timberlake, of Colorado, providing duties on tungsten. The rate of duty on crude tungsten, ores and concentrates, as provided by the bill, is $10 per unit. Metallic tungsten and the various tungsten products and salts, including manufactured materials containing tungsten, are to pay duty at the rate of $1 per lb. The vote on the bill was along party lines, with the exception of Representative Martin, of Louisiana, a Democrat, who voted with the Republicans. The Democrats favor the licensing plan, rather than a tariff. The committee also reported favorably Representative Bacharach's bill providing duties on laboratory glass and porcelain ware, optical glass, scientific and surgical instruments. The rates of duty prescribed under the bill are as follows: Glasswares and porcelain wares, laboratory apparatus, and other apparatus and appliances wholly or in part of glass or porcelain, for use in the sciences or in analyzing or testing or for use in education, 60 per centum ad valorem. Optical glass in any and all forms of glass for use in optical instruments or for any optical purposes, and all instruments and appliances of any and all kinds containing parts of optical glass or used for optical purposes, finished or unfinished, 45 per centum ad valorem. Philosophical, scientific, and laboratory apparatus, utensils, instruments, and appliances and parts thereof, finished or unfinished, and preparations, including bottles and boxes containing the same, not otherwise provided for, 45 per centum ad valorem. Surgical and dental instruments, or parts thereof, made wholly or in part of iron, steel, copper, brass, nickel, aluminum, or other metal, finished or unfinished, 60 per centum ad valorem. DYES, POTASH AND MAGNESITE STILL UNDER The committee, at this writing, still has under consideration the dyestuffs bill and the potash bill, as well as that providing a duty on imports of magnesite. It is believed that the committee is likely to report out substantially the revised Longworth dye bill. In addition to specifying a free list and providing a rate of tariff for the dutiable list, the bill provides for a dye licensing commission as outlined in our issue for July 15, p. 65. The commission shall issue licenses for such dyes as may be unobtainable from domestic sources and shall limit importations as nearly as possible to quantities. required by current needs in the United States. |