NEWS EDITION HARRISON E. HOWE. Editor
Published by the American Chemical Society VOLUME 18
JANUARY 10, 1940
NUMBER 1
Industrial Research in 1939 Advances in the United States and Other Countries WILLIAM A. HAMOR Mellon Institute, Pittsburgh, Penna.
A
NOTHER year has been recorded in the history of applied science—a year of increased usefulness almost everywhere, with new research opportunities in many lands and also new scientific trials, especially in Europc. In general, scientific investigation was more beneficial in 1939 than ever before in facilitating and safeguarding traffic along the highway of industrial progress. Evcn in the warring countries there were found many new technical facts in the side roads to conflict — bright shafts of research accomplishment that in part at least are more significant scientifically than merely as additions to the quivers of combat. In the countries at war the industrial research is, of course, directed by national interest. It is true nevertheless that some of the results of such intense investigation are of widespread permanent value. In the United States industrial research has a pleasant thoroughfare, along which it has kept advancing. The principal results of its progress in 1939 are seen in the field of synthetic organic chemistry, including hydrocarbon derivatives, fine chemicals, plastics, and textile fibers. The petroleum industry, always scienceminded, has kept pace with the requirements of aviation by speedily making available satisfactory and adequate gasoline for airplane use. Metallurgy, glass technology, and building science have been helped forward by numerous improvements. In other countries, especially Great Britain, France, Italy, and Germany, the main subjects of research have been basically similar, and, as in the United States, the most impressive strides have occurred in plastics technology. In view of the present international situation, a trend of vast purport during the past year has been toward the utilization of plastics by the armed forces of every major nation. Military applications of plastics, definite and potential.
resins, the use of such a plastic as Koroseal in gas masks for protection against mustard gas, the application of cellulose acetate in soldiers' goggles, the use of phenolics in the construction of the noses of anticraft shells, and the passible application of nylon as a parachute material. In three British fighting services the uses of synthetic resins are said to exceed 1000 in number, and many recent German investigations have pertained to the employment of plastics in airplane construction.
United Slates
Courtesy, Aluminum
Co. of American
Unsinkablc sailboat with all-Aluminum welded hull include not only the use of laminated materials in airplane construction, cast resins in guide Unes on airplane carriers, and luminescent resins in various military devices, but also the utilization of tinted cellulose acetate windows for air-raid protection, the fabrication of gun stocks from cellulose acetate and from fabric-filled phenolic resins, the employment of shaped cellulose acetate sheet as a chute for conveying ammunition belts from ammunition boxes to machine guns for use in airplanes, the molding of mouthpieces and containers for gas masks from phenolic 1
In 1939 there were very nearly 32,000 scientists and engineers with about 16,000 persons of assistant or clerical grade engaged in research on behalf of 2000 individual companies of the United States. Assuming these figures to be approximately correct, over $190,000,000, probably as much as $215,000,000, was expended by these manufacturers in supporting industrial research. The chemical, petroleum, and electrical laboratories had close to half the industrial research workers of the country. About 110 individual companies in the field of chemical industry and 40 trade associations are making research grants to educational institutions. There are approximately 200 college laboratories that art» used not only for purposes of instruction, but also to a considerable extent for industrial research work and for commercial testing. About 2 5 0 manufacturing corporations are sustaining long-range investigations in research foundations. A considerable number of companies, mostly small concerns that have no laboratories of their own, or larger companies that encounter few problems or are engaging in research for the first time, are regular or occasional clients of consulting labora-
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VOL. 18. NO. 1
$2,000,000 would result from the development of a chemical to inhibit the corrosive effects of brine from refrigerator carr on equipment, track, and bridges. The California Fruit Growers Exchange reported that the research department it set up 25 years ago had yielded investigational results that so far have paid more than $8,000,000 in direct profits to growers and have led to two by-product plants. The American Telephone & Telegraph Co. announced that it would erect a new laboratory at Murray Hill, N. J., at a cost of $3,000,000; the construction is expected to be finished in 1941, to house 800 workers. Many operating industrial research laboratories were increased in facilities and personnel. The New York World's Fair and the Golden Gate International Exposition had exhibits of interesting recent research creations of American industrial laboratories. Courtesy. National Bureau of Standards
Racking load test of a wall specimen tories. There are said to be 250 of these commercial laboratories in the country, and some of them are strongly staffed and excellently equippped for scientific investigation, particularly in specific industries. In this article reference is had to scientific investigations of production problems and not to reseat a concerned primarily with the distribution of goods ("commercial research"). During the year the cornerstones of all the regional research laboratories of the Bureau of Agricultural Chemistry and Engineering, Tinted States Department of Agriculture, were laid. Senate Document No. 65, 76th Congress, 1st Session, April 6, 1939, on "Regional Research Laboratories, Department of Agriculture", is a mine of information on problems, present research, and proposed investigations in the vast domain of agricultural products. The National Bureau of Standards had a staff of 950 employees and SO research associates. Its appropriation for the year was $2,615,000, including $500,000 for a new high-voltage laboratory. This bureau added valuably to the knowledge of housing constructional materials, having an appropriation of $198,000 for the investigation. The research expenditures of the Federal Government totaled about $60,000,000 in 1939. The National Research Council has recently started a survey of scientific investigation in the industries of the United States. E. I. du Pont de Nemours & Co., Inc., had a research budget totaling $7,000,000. A number of other chemical manufacturing concerns had large investigational expenditures. For example, the Dow Chemical Co. spent $1,400,000 on research. Experimental and developmental work was active
among the producers of equipment and equipment materials, 42 companies employing about 1190 men on research. Investigations for the improvement of fan and tower design were carried on aggressively; new types of agitators, ball mills, blowers, control devices, dryers, dust collectors, electric heating elements, fire extinguishers, moisture eliminators, pumps, safety appliances, screen cloths, and vibrating sifters were introduced during the year. Many of these improvements and also a large number of new chemical products were displayed at the 17th Exposition of Chemical Industries. The automobile industry saved more than $10,000,000 by salvaging waste materials. The Associât ion of American Railroads predicted that annual savings of
Industrial Hygiene In 1939, largely under the leadership of the Air Hygiene Foundation of America, many advances were made in coping with the numerous health hazards in American industries. Silicosis, plumbism, effects of chlorinated hydrocarbons and other aliphatic derivatives, and benzene poisoning were studied. The anthracite, granite, cement, and viscose rayon industries received special attention. It is said that occupational skin diseases are increasing and that one out of every one hundred industrial workers in the United States, not including office employees, is affected each year; the annual loss is estimated at $4,000.000. The University of Illinois published a comprehensive survey of sulfur dioxide contamination in Chicago and vicinity. Air hygiene has made entrance in a new way in aviation—an airline in-
Research Laboratories. American Cyanamid & Chemical Corp.. Stamford, Conn.
The AMERICAN CHEMICAL SOCEITY asssures no responsibility for the statements and opinions advanced by contributors to its publications. Published by the AMERICAN CHEMICAL SOCIETY. Publication Office. 20th & Northampton Sta.. Easton. Penna. Editorial Office. Room 706. Mill* Building Washington. I). ('.; Telephone. National 0848; Cable. Jiechem < Washington ι. Advertising Department. 332 West 42nd St.. N-w York. Ν. Υ.; Telephone. Bryant 1* 4430 Entered aa second-claa» matter at the Poat Office at Η a · ton. Penna.. under the act of March 3. 1879. as 24 tm.~, a year on the 10th and 25th Acceptance for mailing at special rate of postage provided for in Section 1103. Act of October 3. 1917, authorised July 13. 191b Annual subscription rate. $2.00. Foreign postage to oouatne· not in the Pan American Union. .60; Canadian postage. $0.20. Single copies. $0.15. Special rates to members
JANUARY 10,1940
NEWS EDITION
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stalled on transports equipment for providing oxygen to crews and passengers during high-altitude flights. Since the ad vent of commercial aeronautics, its ex perts have been cognizant of the need for and value of urban and even regional air pollution control in the main manufactur ing sections of the country.
Mineral Technology Useful information on the effects pro duced by ground movements resulting from the firing of blasts upon buildings in the vicinity of quarries is being obtained by the U. S. Bureau of Mines in a test adit operated at Mt. Weather, Va. Ε. Ι. du Pont de Nemours & Co., Inc., put on the market a new series of Gelobel permissible explosives, designated A, B, C, formulated chiefly for use in coal mines. Nitramon S is a new blasting agent for seismic pros pecting by the reflection method. Airmite is an improved lampblack for use as an ab sorber for liquid oxygen explosives (LOX). During the year the Bureau of Mines in vestigated the design of respiratory protec tive devices, collection and treatment of coal dust in mines, ignition of firedamp by explosives, expansion of coal during coking, washability of coal, effect of acid treat ment upon the ultimate recovery of pe troleum, explosion and fire hazards of com bustible anesthetics, treatment of alunite with boric acid, flotation of southern Illinois lead-zinc-fluorspar ores, flotation of silver minerals, asphalts from Wyoming petroleum, carbonizing properties of coal, acid-resistant pipe, oxidation of anthracite, mine ventilation, processing of gypsum and anhydrite, marketing of salt and talc, effect of atmospheric sulfur compounds on various materials, concentration of sulfur
Electrolytic manganese pilot plant, U. S. Bureau of Mines, Reno, Nev. the foreground compounds in city air, tin deposits of the Black Hills, fireproofing mine shafts, and various koniologic problems, including industrial dust-prevention procedures. The Bureau of Mines described the pilotscale continuous hydrogenation plant at its Pittsburgh Station. Progress was made in researches on improving coal pulverization procedures and also colloidal fuel. Detailed results of the use of anthracite ashes for soil improvement were published. It has been reported that low-grade manganese ores within the country can be utilized by electrodepositing the manganese from sul
Hydrogen-producing unit, coal hydrogenation plant. Central Experiment Station, U. S. Bureau of Mines, Pittsburgh, Penna.
The cell is in
fate solutions leached from them. Ac cording to experiments conducted by the Bureau of Mines, the flotation process may supplant or supplement smelting and cyanidation as a method for the treatment of many silver ores. American Cyanamid & Chemical Corp. developed a new series of flotation reagents for pyritic gold ores containing carbonaceous gangue, making it possible for mining concerns to cyanide concentrates that were previously shipped to smelters for final treatment. Plans for marketing Alsifilm have not been laid down, but much has been learned about the product since the beginning of 1939. Bentonite samples from some two score domestic and foreign sources have been examined, and material yielding about 75 per cent of the ultrafine or col loidal particles and otherwise suitable for the process has been accepted tentatively for commercial operations. Alsifilm can be made fairly strong, flexible, creaseproof, tear resistant, and waterproof, but it has been difficult to develop all these desirable mechanical properties and still retain the dielectric strength and other good electrical properties. At one time it was hoped that the material could be made in any desired thickness; but fur ther study has indicated that where films are built up, one on top of another, the quality of the product suffers, so efforts are now directed toward producing laminated products by employing suitable binders in much the same way as mica is built up from splittings. An electric motor manu facturer is punching out laminated Alsi film for evaluation as commutator insula tion segments. Another manufacturer is experimenting with Alsifilm-coated cloth for window shades. Still another com pany is investigating the utility of Alsifilm
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CHEMICAL AND CHEMICAL ENGINEERING NEWS chemical substances, which, when added in very small amounts during the dry grinding of portland cement clinker, have the ability of increasing grinding efficiency and thereby reducing grinding costs. Colloidal carbon (Cem Beads) is finding increasing use as a grinding aid. New colors for cement mortar were brought out during the year. Pinite was proposed for application in refractories technology. Sintered c. P. alumina came into use for the production of a refractory. A new series of cast fused refractories (Monofrax) as receiving special recognition in the glass industry. Porcelain enameled roofing sheets were tried and found promising for industrial purj>oscs.
Glass Technology
Courtesy, l'ittsburgh Corning Corp.
Block diffuses excessive sunlight in large wall areas as an electric cable insulator. Alsifilm can be produced in films ranging from 0.001 inch and slightly thinner to 0.005 inch; unlike mica, according to claims, it can be filmed in practically any width and length. Uses of vermivulite are increasing and taking new forms. The essential feature of the Watson processes is the production of Watsonite, which in effect is dehydrated muscovite heated carefully to avoid distortion. By employing flexible binders, it is said, coatings of Watsonite can be made on paper, cambric, and other tapes; and by utilizing an inorganic binder, rigid products can be molded. Plans were announced by the International Agricultural Corp. for the expenditure of about $2,500,000 for the mining and processing of potash minerals near Carlsbad, X. Mex. American Cyanamid & Chemical Corp. embarked on the large-scale production of salt cake from brines in western Texas. The process of the Mathieson Alkali Works for the manufacture of anhydrous sodium sulfate, described in 1938, will soon be in industrial use. These developments in the domestic production of salt cake are momentous in view of the demand for it and the recent importation of large quantities of the natural product from Canada and Chile.
Outstanding in the glass industry was the development of safety glass for use particularly in automobile windshields combining the rubbery strength of polyvinyl acetal plastic with plate glass to produce a safety glass of great strength under all temperature conditions, but also sufficiently yielding to reduce passenger injuries on impact with it. This material is very largely used in the 1940 automobiles. Duplate and Duolite are laminated plate glass and window glass, respectively, made with the use of Vinal plastic by the Pittsburgh Plate Glass Co. Document glass is another laminated product. Fiberglas is now being supplied for ser. · ice in 565 groups of products. Fiberglas insulation is said to permit a substantial reduction in the size and weight of motors; moreover, motors so insulated may oper-
VOL. 18, NO. 1
ate at higher temperatures than those with other types of insulation. It is expected that production problems underlying the printing of glass textile fabrics will be solved later. Then Fiberglas prints will begin their destiny as window drapes, door hangings, and end-table covers. A nontransparent glass block patterned in curved ribbed arrangement to give decorative effects is being produced. An important development in the field of structural glass has been accomplished by the design of a new glass block containing a sheet of Fiberglas sealed into the block. The insertion of the Fiberglas increases the insulating value of the unit and makes it of particular interest where a welldiffused light is desired combined with the other advantages of glass-block construction. A typical unit of the newer design transmits 55 per cent as much energy as the older block and 75 per cent as much light with a marked increase in light diffusion. Hollow glass block research is under way at Purdue University. An ultralow-expansion glass has been developed which promises the possibility of manufacture by mass production method of glass cooking utensils having properties superior to previous glass dishes, at a reasonable cost. It is prepared by leaching out of a special glass the nonsiliceous components, leaving a network of nearly pure silica which, by baking at high temperature, fuses into a completely trans--rent glass resembling fused quartz. It is extremely resistant to breakage under violent temperature changes. This development has not yet been carried to the commercial stage. To meet the demand
Ceramics In 1939 marked advances were made in phase equilibrium studies of portland cement clinker. A better understanding of methods of estimating clinker composition was obtained as a result of researches on the quaternary system CaO-Al2O2SiO2-Fe2O3 and the minor constituents and glassy phase which exist in clinker. Attention bas been given to various active
Courtesy, Corning Glass Works
New Corning ultralow-cxpansion glass docs not break when subjected to sudden changes of hot and cold. The small dish, which rests on the cake of ice, is being heated by an oxygas flame
JANUARY 10, 1940
NEWS EDITION
S
Courtesy. U. S. Steel Corp.
Austempering equipment of American Steel & Wire Co., Worcester, Mass. for light-colored writing boards which will improve the illumination and appearance of school rooms, a glass writing board has been evolved in various colors. It has an extremely low reflection from the surface, is well adapted to use with chalk or crayon, and is permanent in finish so that it will not develop a polished reflecting surface on continued use. The Land Polaroid material was further improved for use in eliminating glare. A new process is being utilized in the manufacture of continuous crystalline polarized sheets deposited directly on glass plates. A Union Pacific streamliner is using a new type of Polaroid train window designed to prevent glare from snow and desert sun. The American Optical Co. has developed a novel use for Polaroid in detecting fraudulent claims of industrial eye injuries. Lighting engineers class the fluorescent lamp as an outstanding recent development in lighting. Last year approximately 1,000,000 of these lamps were installed. High intensity mercury lamps were further improved. The sealed beam automobile headlights a new type of gasinsulated x-ray tube, and a process for removing glare from reflected light on glass by the application of thin chemical films to the surface of the glass, came from the General Electric Co.
Metallurgy About $10,000,000 was spent by the steel industry for industrial research. Nearly 2550 scientists are employed, while close to 1300 others devote part of their time to investigational activities. The steel industry has invested more than $9,000,000 in providing facilities for these research workers. About 33 per cent of the expenditure is devoted to the improvement of the quality of products, and 19 per cent is spent in the betterment of manufacturing methods; the develop-
ment of new products represents about 20 per cent of the activities. The world's first air-conditioned blast furnace was erected at Woodward, Ala. Westinghouse metallurgists devised the Ammogas process for the bright hardening of tool steels without surface damage by oxidation and decarburization. Ammogas is a mixture of hydrogen and nitrogen derived from ammonia. Calcium chloride solutions came into use for quenching high-carbon steel. New products for the steel and related industries were put on the market: du Pont carburizing salt and du Pont accelerated salt, both cyanide mixtures; Causticbond, a protective coating for wood or metal exposed to liquid acid or alkali; and Zirconite A, a core and mold wash. The knowledge of metal powders was furthered by research of 1939. It was found that quite small amounts of silver can cut down the salt water corrosion of stainless steels considerably. Silver, moreover, is said to improve the rolling and machinability of the metal. Silverstainless will soon be in commercial production. Titanium tetrachloride was learned to give stainless steel a lustrous and extra-smooth new surface especially resistant to pit corrosion. The Kinkead process consists of alloying the surfaces of steel sheets and shapes with coatings of stainless steel or other metals. Leaded steel, especially machinable, was accorded much study. Information on columbiuiabearing steels was published. New alloys were developed for the automobile industry. Kennametal (WTiC2) is a new compound used chiefly in making alloys for tools. The physical properties of magnesium alloys are under study at the State College of Washington. Among the investigations carried out at the National Bureau of Standards was a broad research on the effects of continuous
weathering on light-metal alloys used in aircraft. During the past five years several leading aircraft manufacturers have developed satisfactory technique for spot welding parts to form structural assemblies. Kovar is a Westinghouse alloy of iron, nickel, cobalt, and manganese that, because of its ability to expand at approximately the same rate as hard glass, has proved efficient in keeping air out of electronic devices after partial evacuation. K-42-B, another new Westinghouse alloy containing 46 per cent nickel, 25 per cent cobalt, 10 per cent ferrotitanium, and 19 per cent chromium, is of promise for high-temperature service because of its remarkable tensile properties at elevated temperatures. Lead-silver airplane bearings are making progress. Cupraloy, a Westinghouse research creation, is an alloy of copper, chro-
A typical Kovar application. Metallic seal formed with two glass ends of an Ignition tube, Westinghouse Research Laboratories
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