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T H E eighth year of the Armour Research Foundation, while witnessing the same growth and expansion of public services which characterized earlier years, has been m a r k e d in several significant ways. Most particularly it has been a year of self-analysis, inventory, and orientation. T h e progressive increase in research services t o the Nation, its industry, and the general public, whose appropriations and contributions for this purpose h a v e grown from $30,000 in the first year of the founda t i o n ' s existence to $1,66S,845 in the year j u s t concluded, a n d the extension of this service under the growing external demand for an organization of international scope, clearly indicate the need for careful planning a n d balancing of all phases of the work in order t h a t the organization may serve to t h e maximum possible public benefit. Accordingly, this theme, although popularly referred to adnauseum as "postw a r planning", was nevertheless the outs t a n d i n g topic of this year's N o r t h Woods S u m m e r Planning Conference. Out of this h a s come w h a t is hoped to be a reasonably accurate estimate a n d recognition of t h e responsibility which the foundation must bear in the coming decade. The meeting of increased urgent dem a n d s for research service to our Armed Forces and their industrial suppliers has been absolutely necessary and must still continue a t the expense of m a n y civilian requirements. Toward softening the technical reconversion shock which m u s t come, sponsors have been urged to plan their research for immediate military needs with a simultaneous regard for peacetime applications of the results where possible. T h e foundation has considered that acceptance of additional research must be governed b y efficiency limitations, lest all projects suffer through dilution of effort. During t h e past fiscal year 117 longterm projects h a v e been in operation, including 55 new investigations. Since the Seventh A n n u a l R e p o r t (/), 701 additional short-term studies have been cond u c t e d . T o d a t e , t h e foundation has u n d e r t a k e n 262 major research programs, together w i t h 5,504 short-term studies a n d special tests, serving a total of 1,615 large and small companies, associations of manufacturers, a n d governmental agencies. Ninety-four long-term industrial research projects are in operation a t present.
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een rpublished also in Spanish a n d distributed bj t h e Corporation para la Promociont del Intercambio in Buenos Aires. The foundation bias been commissioned to make a somewhat sincailar technological audit of Mexican industries, under the sponsorship of .the DBanco de IMéxico, with initial industrial eroi:has5isupon fibers and their industrialization, fciidcs and leather, coal, coke, other solid feiels a n d by-products, and forest prodiie~ts in. general, together w i t h the necessa-ry related industries, resources, a n d techanological aspects. From the foundation's field neadquarters in Mexico City, t h e workz will involve careful study of all regions o f Mexico from this standpoint, in close collaboration with Mexican technologists, A s a further a i d to N^Iexican industrial development, t h e foundation has arranged for a number o f outstanding young Mexican scientific m e n to co>me t o the United States for a mimbex of years' work in laboratories, supplementing^ this with advanced graduate training i n any of the universities or technological institutions in the Chicago area,.
Specia I Public Services I n addition t o tfre basic p-rogram of the foundation in research f o r advancement of the useful knowledge of science, every effort is made to- obtain t h e maximum public service froia. the aggregate facilities. Thus it h a s been possible to contribute t o
M o b i l e field laboratory for stress studies
the general public benefit in an increasing number of ways other than through the research projects. National Registry of Rare Chemicals. N o w firmly established as a necessary part of the scientific scene, in its third year of operation the National Registry of Rare Chemicals continues to serve the technical professions and industries throughout the world. The Armour Research Foundation, in maintaining this free public service, considers the success of the Registry due in a large measure t o the unified cooperation of the major scientific societies, industries, and individual scientific workers everywhere. From laboratories and plants in the United States, South America, England, Australia, South Africa, India, Canada, and Mexico, have come over 3,400 requests for unusual compounds needed in research or production. As the central clearinghouse for information on the location and availability of rare chemicals, the registry has been able to fill approximately 75 per cent of these inquiries. The registry does not stock, buy, or sell chemicals, but merely serves as a locating agency and information source. I t s files have grown to include sources for more than
Oner of t h e chemical engineering research laboratories
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2 3 » DECEMBER
10,
1944
8,000 rare chemicals not listed by regular suppliers. Wire Recorder Program. One of the foundation's contributions to a growing number of' channels of public benefit is the service rendered through the magnetic wire sound recorder. Quite apart from its creation of postwar employment and its commercial aspects as a new industry, this recently developed recorder has provided an unexcelled opportunity for increased world enlightenment and for numerous other public aids. Since t h e ultimate value of research is dependent upon i t s practical availability, the foundation has established a new section to develop educational and industrial uses of wire sound recording. The fact that to date the recorder has been manufactured b y a limited number of licensees for the exclusive use of the Armed Services has not necessarily kept its potential applications unknown in the postwar fields. These applications, to mention but μ few include: h o m e recording in radio receiv ing sets; educational uses in schools» homes, industries, and illiterate world areas; professional records; office and re mote dictation and transcription; police calls; transportation orders on land, sea, and air; remote pickup and broadcasting; court reporting; recording telephone mes sages; and amateur movies. During the past year the foundation has continued its policy of licensing and instructing quali fied manufacturers to produce magnetic wire sound recorders for use in various fields. Although actual production is en tirely absorbed in the many wartime ap plications, this activity is being conducted simultaneously with a view toward post war uses which will render the instrument of value t o t h e maximum number. The fact is, of course, that while achievements in the engineering and manufacturing of recorders for the Armed Services can in some instances be converted to postwar in dustrial applications with reasonable promptness, certain other uses must await the conclusion of additional developments before widest use can be expected. From the foundation's new Chicago loop offices, opened May 31 for the cor relation of these activities, a limited num ber of recorders are being made available
2091
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on loan for certain purposes which will effect meritorious public service and a t the same time provide valuable field test d a t a for study in particular applications. Arrangements h a v e been made for t h e United Nations Relief and Rehabilitation Administration t o experiment with a re corder loaned to t h a t organization for use b y its Balkan Mission. At the outset, this recorder is being utilized successfully to disseminate mass instructions with respect to health and hygiene in camps sheltering more t h a n 35,000 Jugoslav and Greek refugees. In the E a s t and Midwest the U. S. D e partment of Agriculture, to whom a re corder has been loaned also, recently con ducted a series of on-the-spot interviews a t agricultural experiment stations which were later broadcast o n several farm radio programs. These recordings, made in collaboration with s t a t e agricultural col leges and local radio station farm pro gram directors, included such topics as corn pests, animal ailments, and farm de velopments and experiments, and avoided the necessity of h'aving the speakers travel to the broadcasting studios. T h e Library of Congress has an experi mental machine which is expected to re cord on wire, for preservation, the hun dreds of priceless disk records of American folklore music which have been made for the Library's archives. Most recently, the Library of Congress has added to its collection the historical records of the Battle of Saipan, originally recorded by one of t h e early wire recorders built by the foundation. T h e foundation was fortu nate in obtaining this battle-scarred re corder, together with some spools of the Saipan wire records, which will probably be presented to some prominent museum following a series of requested exhibitions throughout the c o u n t r y . T h e recorder's worth t o t h e blind is being demonstrated through the loan of a machine to the American Foundation for the Blind. The Armour Research Foun dation plans to collaborate extensively with 2092
organizations assisting the blind, in im plementing the recorder for s t u d y courses and e n t e r t a i n m e n t for the sightless. Λ future highlight of the recorder's value in postwar times is the major part that i t will play in educational projects in schools and colleges, a s well as in connec tion w i t h t h e program of radio education for adults now receiving such great em phasis. Groundwork is being laid through various educational channels t o project the recorder's use in this direction. The U. S. Department of Education is now arranging educational F M networks for state educational systems, a n d the wire recorder will probably be used extensively by schools for playing back these programs a t convenient hours in various classrooms. Similarly, such programs can be recorded at home for use in adult s t u d y courses. Toward furtherance of these objectives, two n e w organizations are in t h e making. A proposed society of licensees for techni cal conferences is under discussion. Mean while, the Wire Recorder Development Corp. has already been granted a charter. The latter contemplates providing an educational record distribution service to sponsors of educational projects. I t will work with wire and wire magazine m a n u facturers t o bring a b o u t mechanical per fection, high standards of quality in the recording medium, low prices of blank wire magazines, and assurance of a convenient source of supply. These things are equally desirable* i n the interests of t h e general public, the machine m a k e r s , a n d the record makers. City Noise Reduction. During t h e past year t h e foundation h a s continued t o assist in t h e activities of t h e Greater Chicago Noise Reduction Council in reducing the unnecessary noises in t h e City of Chicago. Through t h e efforts of t h e Council a n d the City's Noise A b a t e m e n t Commission, Chicago h a s been awarded t h e National Noise Abatement Council's plaque for t h e second consecutive year for outstanding work in noise a b a t e m e n t . Radio Interference. As a national com-
CHEMICAL
mimity contribution, two members of t h e foundation's major physics research staff have been made available for service o n the Committee on Scientific I n s t r u m e n t s for Panel Twelve of the R a d i o Technical Planning Board. This committee, con sisting of physicists from i n d u s t r y and scientific institutions, has been charged with making a study of possible interfer ence with radio reception which might b e caused by scientific instruments. I t s find ings, together with those of t h e other sec tions of t h e Radio Technical Planning Board, will make possible the best utiliza tion of available radio channels. Technical Advisory Services. The foundation has continued to provide gen eral technical advisory service on a s broad a scale as possible. Inasmuch as certain types of technical activities are outside t h e scope of this organization, in a v e r y large number of cases this service h a s consisted of referral of t h e inquiries to appropriate commercial testing laboratories or consult ants. Meanwhile, in addition to its sponsored long- and short-term research studies, t h e foundation has been able to answer directly hundreds of inquiries, either supplying the necessary technical information or suggesting sources where it may be obtained. M a n y of these inquiries have come through t h e Smaller W a r Plants Corp., while others h a v e been re ceived directly from manufacturers a n d individuals in t h e United States, C a n a d a , Latin America, England, a n d elsewhere. T h e greatest use of this service is m a d e by smaller manufacturers, whose technical inquiries are concerned chiefly w i t h stand ard industrial practice, and w h o a r e some times unfamiliar with t h e numerous re search, testing, and consulting facilities available t o t h e m generally.
Industrial Research Projects Since t h e beginning of t h e fiscal year 55 new long-term industrial or governmental research projects have been u n d e r t a k e n : abrasives, air conditioning, a l u m i n u m cast ing, a u t o m a t i c sprinkler control, boiler de-
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scaling, bolts, bushings, cathode ray tube screens, cellulose, chocolate, clays, copper welding, counting devices, crucibles, cutting oils, dental materials, Diesel engine indicators, dry corn milling, electrical networks, electroplating, engine couplings, gas turbine blades, glas fibers, flexible shafting, fountain pens, fuel additives, industrial process war aids, insecticide dispensers, lithography, magnetic recording wire, metal detection, mica beneficiation, milling survey, multiple recording, permanent molds, piston ring gage, potash, powdered metals, protective? coatings, pumps, shade rollers, sound recorder production, stenographic devices, thermocouples, vacuum tubes, wall paper, waterproof fiber containers, wood, and seven projects whose titles cannot be disclosed for security reasons. During the year 30 projects, including 2 4 carried over irom the previous fiscal period and 6 initiated in 1944, were completed: alternating current motors, air cleaners, air injection, annealing, automatic sprinkler control, ceramic molds, cupola operation, electron optics, fanweed seed, gas turbine blades, gear \\Tear, mica processing, milling survey, non ferrous melting, oil refinery equipment,permanent molds, powder metallurgy, railroad brakes, sound recording, steel converter operation, structural lumber, surgical sutures, tank tracks, welding, wire rope, and five in confidential fields. Seven projects are under temporary suspension through the cooperation of their sponsors, t o aid in meeting urgent military research needs : cigar lighters j computing machines, cranes, dynamic loading, golf equipment, pipe bends, and spraying equipment. In all, 117 major research projects have been in operation during the year, exclusive of the 7 under suspension. N i n e t y four projects continue into the coming year, including 49 of the new ones already listed, the 7 suspended, and 38 of from one t o six years' duration. Those of t h e lastnamed group are: acoustic tube, airport loading, airport paving, boiler water conditioning, carbohydrates, cast valves, compressed gases, container glass, core binders, core boring, crane survey, die steel, dolomite, drum closures, electrical weighing, electronic gas analysis, electrotinning, engine lubricants, fibers, filters, gas containers, impact studies, magnesium forging, malting, metal finishing, noise reduction, open-hearth slags, quenching oils, silencers, steel casting, textiles, turntables, watch technology, welding supplies, wheat, wire drawing, and two on confidential subjects. Announceable progress on industrial research projects under way during 1944 follows:
Paint milling in a coating research project
A biochemical research laboratory
Chemistry and Chemical Engineering Research Boiler Water Conditioning. Concerned with the improvement of boiler water treatment, a project under the sponsorship
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Electron-chemistry research laboratory
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2093
of the Dearborn Chemical Co. is in. its second year. Both the theoretical and applied aspects of the problem are being considered con currently. Earlier work with boiler com pounds consisting of mixtures has been discontinued in favor of studies with ma terials whose composition is definitely es tablished. Through subsequent evalua tion of such compounds by means of actual performance in an experimental boiler, it is hoped that the data will indicate the type of molecule required for optimum foam inhibition and period of effective- ness. As an aid to both the theoretical aspects and the evaluation of boiler compounds, high-speed photography has been applied to the study of the characteristics of foams originating from treated and untreated waters. Results so far show considerable difference in the size, shape, and frequency of occurrence of foam bubbles originating at the heating surface. Carbohydrates. Under the sponsorship of E . J. Brach & Sons, a project for the de velopment of controlled manufacturing processes and fundamental studies of starches and other raw materials used in this company's products enters its third year. Studies made on the effect of moisture content of a number of products clearly indicate its importance with respect not only to the initial quality of these products but also to their final quality as they reach the consumer. These findings have led to the development of a procedure affording continuous control and adjustment of a previously determined optimum moisture content. Projected work will be concerned with the development of special raw ma terials and processes to serve as further safeguards against deterioration of the products during storage. Cathode Ray Tube Screens. During the year a comprehensive program for the study of the chemical behavior of cathode ray tube screens was initiated under the sponsorship of the Philco Corp. Complete laboratory facilities for the production of screens and their evaluation have been installed. Essentially in the fundamental stage, it is expected that the final phase will be concerned with the development of new screen materials. Cellulose. An investigation of the manufacture of this vital commodity from certain agricultural waste materials has been initiated by the Sylvania Industrial Corp. A very broad survey of sources of suitable raw materials has been completed, and work is now being directed towards the experimental phases of this project. Chocolate. A research project on the study of basic chocolate coating formiulas was started during the year by the Chase Candy Co. Work has begun with fundamental studies of the physical and chemical princi ples involved in the development of de sired chocolate textures and flavors. Compressed Gases. The study of cer tain gases under pressure is being carried, into the third year. In addition to numer ous plant tests, further work on the compatibility of the gases with other ma terials has been conducted throughout 1944. Dental Products. A broad investigation, of materials used in dental practice was begun during the year. Fundamental studies are now concerned with the physi cal and chemical properties of these ma terials. Upon completion of this part of the program, the second phase will be concerned with the improvement of the materials now under consideration. Drum Closures. Carrying over into its seventh consecutive year, the project of the 2094
American Flange & Manufacturing Co. has continued to deal with the improve ment of gasket materials. Numerous newmaterials were investigated during the year to determine their suitability for use in closures under normal shipping condi tions as well as the severe conditions im posed by use in widely varying climates through shipments to the Armed Forces. Dry Corn Milling. Sponsored by the Chas. A. Krause Milling Co., an extensive survey of the dry corn milling industry has led to the establishment of a project by this company whose primary objectives are (1) improvements in the dry corn mill ing process to obtain a better yield of the more valuable products, and (2) develop ment of new products, and the utilization of these and current products in new indus tries. Fibers. In the third year of the project sponsored by the Hawley Products Co., Tempcro*ure C.ffeci On Bursliog Strength Examples O f Four Tyioicol W o ' e r p r o o l Wrapping M a t e r i a l s
TEMPERATURE/F F.gure2 T e m p e r a t u r e E f f e c i Or Tensile S t r e n g t h Fou· Typicol W a t e r p r o o f ••ols
TEMPE RATURE. Τ Fïqure 3 T E M P E R A T U R E EFFECT ON S T R E T C H I N G PROPERTIES Four Typical W e r p r o c / W O p p i n q Materials a - Machine Direc tioo " b · Cross Direction "
TEMPERATURE.
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fundamental work on fiber structure has been continued. The pilot plant for developmental work was greatly enlarged and equipped with additional facilities and specialized testing apparatus. Two major research programs were successfully completed during the year. These arc (1) development of a simplified pulping process for producing a pulp from oat straw without the aid of heat or pressure and a minimum amount of chemicals; and (2) an intensive study of the effect of wet strength resins on the Mullen and tensile strengths of specialized pulps used by the Hawley process. The following table summarizes the relative properties of the oat straw pulp to Northern Kraft, showing an interesting comparison: PROPERTY
KRAFT
STRAW
Mullen Tensile Abrasion Flexibility Stiffness Normal freeness range— seconds Cost per ton as usable pulp
Excellent Good Poor Good Poor
Good Excellent Excellent Poor Excellent
10 to 100 40 to 500 180.00 $30.00
Studies of the wet strength of three pulps—Kraft, super alpha, and oat straw —for both the wet-strength-treated and the untreated pulps, show that the full wet strength advantages are only brought out if accurate temperature control is maintained. Filters. A research program for the Cuno Engineering Corp., Meriden, Conn., on the problem of nitration is going into its third year. In addition to fundamental studies of various types of filtering media, filters for several specific applications have been developed for use by the Armed Forces. Studies are being continued on several additional phases of this very broad program. Among these are (1) the production of certain types of filter cartridges by entirely new manufacturing processes; and (2) correlation of laboratory tests on filters with accelerated engine wear tests. Foundry Core Binders. The original aim of the project for the Quaker Chemical Products Corp.—the development of a new t}rpe of foundry core binder—appears to have been realized and large-scale plant tests are being made. The new binder acts as both a green and baked-strength binder, with consequent savings in cost over the conventional types. The following table compares the baked and green strength of the new type of binder with the commonly used linseed oil and cereal combination.
CORE BINDER
ARF binder Linseed oil—Cereal combination
BAKED STRENGTH AS TRANSVERSE STRENGTH
(lbs./sq. in.) 62
GREEN STRENGTH
(oz./eq. in.) 12.4 7.3
Industrial Process War Aids. Apart from specific major research projects, a general wartime technical service is being rendered to the Industrial Processes Branch of the OPRD. Under a blanket agreement with this War Production Board agency, the foundation lends scientific assistance on all topics on which there is no conflict of interest with other research commitments. This work has included special studies and technical aid on colloidal fuel, dental equipment, fuel gas generation, package liners, pipe reamers, radio condensers, and shipyard chisels.
CH HEMIC CA A LL A N ND D
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The packaging question is particularly interesting, for the present demand for kraft paper suitable for overseas packaging has created a serious shortage. Of various substitute materials, one which seems to be receiving excellent acceptance is an asphalt impregnated cotton batting using low-grade short fiber cotton. Much has been learned in the last few years about the protection of shipments by proper shock insulation, adequate bracing, and especially the use of barriers to the atmosphere. However, the properties of all asphaltic papers, which are frequently used for these barriers, are shown to vary greatly with temperature changes. The accompanying diagrams show relative bursting strength, tensile strength, and stretching ability for several of the widely used asphaltic papers and for the asphaltirnpregnated batting, the latter designated as No. 3. Property differences noted between the "machine direction" and the "cross direction" in manufacture are indicative of the amount of research and improvement which should be done on many packaging materials to give products of greater uniformity. I t is also desirable to improve the tensile and bursting strength a t higher temperatures and flexibility or stretch a t lower temperatures. Malting. Established a year ago by the Rahr Malting Co., this project is being continued on greatly enlarged scale. The broad objective of utilizing the plant facili-
À corner of the new unit process laboratory
ties for processing a wide variety of agricultural materials, together with the application of their products, has necessitated expansion of the investigation into a number of other industries. During the first year of this study, rather complete data have been established experimentally on the products obtained by the malting of a great variety of seeds. It is interesting that certain seeds produce a relatively pure alpha-amylase, while others are found to be deficient in the alpha form but rich in almost pure beta-amylase. Work is in progress toward applying these findings to industrial processes in which limited and specific enzymatic action is desirable. By using the sources of relatively pure amylases instead of mixtures obtained in malts, it is possible to achieve a better control of the products of enzyme action. The accompanying table shows the importance of the quantitative relationships of the two enzymes in the baking industry. The enzymes were derived relatively free from other amylases from different seeds. The role of alpha-amylase in providing good crumb characteristics and of betaamylase in developing loaf volume is evident. ALPHAAMYLASE EQUIVALENTS"
α
Measuring tensile strength in new paper development
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NO.
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DECEMBER
10,
1944
BETA-
AM YL AS Ε EQUIVA LENTS0
LOAF VOLUME
TEXTUBE SCORE
cc. 748 779 770 789 820 807 826 835 Based on values for malted wheat flour.
Metal Finishing. This project, now in its third year, has for its purpose the exten sion of knowledge of metals finishing operations and the ultimate compounding of metals finishing materials on the basis of actual performance. Protective Coatings. A comprehensive program to study coatings for application to wire is being sponsored by the Page Steel & Wire Division of the American Chain and Cable Co., Inc. The goal is to 2095
widely divergent results obtained from several waterproofing agents.
WATER PROOFING AGENT A Β C D Ε
M U L L E N BURSTING STRENGTH (AVERAGE) Dry
24 Hours water immersion
170 200 190 210 200
0 0 20 1Λ0 160
Wheat. The project in wheat and its products enters its fourth consecutive year. Initially launched as à study of the milling process, the program has been broadened from year to year to include fundamental studies on storage of flour, and the influence of aging upon baking characteristic% Work on the latter phase is exceptionally comprehensive and should result not only in a better understanding of the chemical changes taking place during aging, but also, through eliminating undesirable changes and accelerating those which are favorable, in a n improved bread. Ceramic Materials Research Baking studies in a grain research program
develop coatings which will not only have high resistance to weathering, but will at the same time be compatible with the trend among progressive architects and designers to harness functionality and "eye appeal". Complete laboratory facilities for evaluation of coatings have been in stalled, and a survey of promising materi als is nearing completion. Quenching Oils. During the first year of a project on quenching media, sponsored by the Shell Oil Co., the investigation has been devoted primarily to a study of the metallurgical, physical, and thermal phe nomena associated with the quenching operation. The information being gath ered from the experimental studies is being used in an attempt to develop improved quenching media for specific requirements. Surgical Sutures. The Johnson Suture Corp. project was concluded during the year. This investigation was primarily de voted to a detailed study of the various operations involved in the manufacture of sutures. Considerable value was re ceived from an instrument specifically developed for the measurement of surface contours, in correlating manufacturing techniques with performance of the final product. Textiles. The project sponsored by the Joanna Textile Mills enters its second year. Several new phases of this investigation have been incorporated into the research program. The study of starches previously re ported was continued throughout the year, and has resulted in the applicability of domestic cereal starches in the manufac ture of tracing cloth. Since such starches require a special treatment in order to produce tracing cloth having a degree of opacity which remains low after aging, a starch conversion plant is being assembled. As an aid to further development as well as production control, an instrument has been developed to measure the rough ness of coated and impregnated fabrics. Work on waterproof rubber hoi lands has been continued, although on a scale somewhat limited by .difficulties in ob taining certain coating materials. Funda mental studies on the mechanical jispects of coating have been continued with spe cial emphasis on emulsion coating. New equipment has been adc^ed to the pilot 2096
plant. A friction calender has been de signed and is now being constructed; its installation will complete the pilot plant and "will make it adaptable to practically all coating problems which may be en countered. Strictly in the * textile field, work has been conducted during the year on the de velopment of a water-soluble cotton warp size, unaffected by atmospheric changes and removable from the cotton cloth by immersion in water, thus eliminating the enzyme treatment required for the removal of the conventional starch size. Additional advantages are incurred through high tensile strength and elongation values im parted to the cotton warp. A comparison of these values for starch size and the water-soluble size follows:
WARP SIZE
AVERAGE TENSILE0 STRENGTH— OUNCES
AVERAGE PERCENT ELONGATION0
Starch size 11.0 3.6 13.3 4.3 New size ° Average of several hundred determinations.
Wall Paper. Under the sponsorship of the Lennon Wall Paper Co., a project for the improvement of wall paper manufac turing processes was begun during the year. In view of the close relationship be tween the various raw materials employed in this process and their mechanical treat ment, both phases are being investigated concurrently. For future work it is ex pected that a complete pilot plant will be set up. Waterproof Fiber Containers. A project for the O P R D Branch of the W P B has been undertaken to develop means of waterproofing domestic corrugated fiber boxes for overseas shipment. The enor mous demand for such containers by the Armed Forces has made such a program of paramount importance, since the supply of V-type waterproof boxes is limited. Equipment for coating and testing con tainers has been set up and a procedure which allows rapid elimination of poor coating materials has been developed. For a final test the coated boxes are subjected t o both water immersion and spray tests. In the accompanying table are shown the C H E M I C A L
Ceramic Molds. Continuing from last year, further work has been done on the possibility of developing a semipermanent ceramic mold. Bodies of many different compositions have been investigated in attempts to find a composition capable of withstanding high thermal shock. At the same time, the mold is required to produce intricate detail on the many successive castings in actual production. Progress has been made, but the ideal composition has not been discovered. Clays. Investigations have been in progress for t h e past year with the object of developing certain types of produf : J i±^i usually associated with common clays. The study involves thorough -hnmical and pétrographie examinations of the clays, which are fired under, different atmospheric conditions with careful temperature control. This investigation has met with considerable success. Container Glass. Two years of work on the glass project, sponsored by the Liberty Glass Co., Sapulpa, Okla., have been completed. During the second year the investigation has principally centered around composition and its effect on physical properties during processing. The acquisition of new equipment has substantially increased the facilities for further studies. Crucibles. Work is being organized on a program to investigate crucibles for the melting of metals. The study will involve the examination of materials developed during the past few years which might be considered suitable. Dolomite. Studies continue on the calcination of dolomite and its subsequent hydration for the Marblehead Lime Co., in an. attempt t o develop magnesium hydroxide in greater purity than previously obtained. As a further feature of this investigation, efforts are being directed toward the production of magnesia having structural properties that will produce a light, fluffy powder suitable for certain industrial processes. These studies are the outcome o f an investigation t o derive magnesia from dolomite for refractory purposes for the same company. Particle Size Distribution. A project on the size distribution of powdered metals, sponsored by the O P R D . has proved to be of considerable interest. Through the cooperation of the Portland Cement Association, various procedures for determination of particle size have been inAND
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vestigated. The most promising involves measurement of the intensity of a light beam as it is interrupted by particles settling in a liquid. The procedure is similar t o that of the Wagner turbidimeter commonly used for particle size determinations of Portland cement. A second pliase of this project is a study •of air-separation of particle sizes for commercial-scale application. Steel Converter Refractories. A project sponsored by the Whiting Corp. on the development of better refractories for the side-blow converter has been completed, -and the work released for publication through the official organ of t h e American Poimdrymen's Association. A new monolithic silica mixture was found t o give better than 100% increase in the side-blow converter lining life. In addition, the evenness with which this lining wears has resulted in a much smoother blow and a more efficient converter operation. In one case where this mixture has been adopted as standard practice the actual blow losses were reduced from 23 t o 1 1 % . The composition of the most satisfactory mixture by weight is as follows : 50.0% 30.0% 14.0% 6.0%
0.375-inch silica ganister 0.125-inch silica ganister 140-mesh silica flour pulverized western bentonite Experimental de-airing and extruding of c l a y
100.0% 7 . 5 % water
Ladles lined with this mixture and handling steel at 3200° F. show from two to four times the life of those thought t o have good possibilities for use in other furnaces. M e t a l s Research Aluminum Casting. Ebaloy Foundries, Inc., has set up an extensive project on improvements in the casting technique of aluminum alloys and the development of alloys with improved properties. In connection with the casting technique, the emphasis is placed on reduction of rejects eaused by pinhole porosity. Boiler Descaling. Research in this field has been undertaken during the year on behalf of the Butler Engineering Co., N e w Orleans. An electrolytic device manufactured by this company for the removal and prevention of boiler scale is being subjected to intensive study. T h e operation of such devices is little understood, and it is therefore the first aim of this project to find a scientific explanation of their action in boiler operation. T h e next step will be to make use of such knowledge to improve the efficiency of t h e instrument, and to extend the range of conditions under which it will operate successfully. Cupola Operation. Research on cupola operation, started last year under the sponsorship of the Whiting Corp.,' has continued. The primary object of this research is to study the effects of moisture content and preheating of cupola air. On the basis of chemical analyses of cupola gases under different experimental conditions, an analysis of the nature of cupola combustion reactions has resulted which, when treated thermodynamicaliy, yields much valuable information. General equations have been developed with which one may calculate the maximum theoretical combustion temperatures and heats of reaction under different conditions of moisture content, preheating temperature, and combustion gas analysis. These equations show clearly the relative importance of moisture control and preheating. Die Steel. The fundamental study of hardenability has continued, under the sponsorship of A. Finkl and Sons Co». Primary attention has been directed to V O L U M E
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Cu-Pro-Die steel which exhibits an extraordinary hardenability. A quenching dilatometer has been designed and constructed which facilitates the study of isothermal transformation in steel. When a definite knowledge of the mechanism is available, it should be possible to suggest means for still further development. Electroplating. This project, having as its objective the improvement of electrolytic tinplate, is in its third year and has resulted in several interesting developments. Among them are: a rapid electrolytic thickness tester for tinplate; a similar device for the older hot-dip tinplate; an "electrographic" porosity testing method and device; an instrument for studying the oxide film on tinplate in connection with lacquer adherence; a n d a method of preparing cine-photomicrographs of the fusion-brightening of tinplate. The latter technique has produced a short 16-mm. film which discloses the phenomena accompanying such brightening. Considerable work has been done o n the use of undercoats of a second metal between the steel base and the tin layer. Several tin alloys have also been plated and tested for possible usefulness i n tinplate. In addition to plating experiments, studies are in progress on the fundamental electrochemical nature of the corrosion of tinplate in various media simulating actual food packs. Magnesium Forging. The research program on the forging of magnesium alloys has been continued into its third year. The comparison between extruded and cast forging slugs has been studied. For some special shapes precast permanent mold forging slugs have been found to be more economical than extruded materials. Forgingshave been made with multiple press operation to minimize preferred orientation. Nonferrous Melting. During the past year, research has been conducted o n the development of a more efficient method for melting nonferrous mefals, with particular attention to the magnesium alloys. A radiant burner type furnace has been constructed and compared with the conventional gas-burning type furnace. Pot
23 . D E C E M B E R
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1944
scaling has been noticeably diminished and gas consumption reduced t o 4 0 % of that of the conventional type furnace. Open-Hearth Furnace Slags. Research on basic open-hearth furnace slags, sponsored by the Inland Steel Co., has continued into its fourth year. I n this program, pétrographie methods have been employed to determine the mineral constitution of chilled slag samples. During the past year, finishing slags from 36 heats —covering all grades o f plain carbon steel and a wide range of conditions—have been studied to ascertain the effects of different deoxidation practices and materials upon the final product- Correlation of pétrographie data a n d chemical analyses of metal bath samples s h o w s general relationships t o exist between slag maturity and finishing practice and the slag's ability to retain phosphorus. Powder Metallurgy· I n t h e field of powder metallurgy, b o t h practical and fundamental problems have been considered during t h e past; year. One sponsor was concerned with making a small, high-strength part b y the powder metal technique. This part was formerly made b y shearing and machining in many operations. B y means of powder metallurgy, a satisfactory high-strength part was made which eliminated most of the expensive machining. Studies were made also of porous materials produced by means of powder metallurgy. T h e effects of certain variables on physical properties were correlated. These variables included type and shape of powder particles, mesh size, pressing and sintering schedule. Side Blow Converter Operation. The Whiting Corp. h a s also sponsored a study of the side-blow converter, with a view to perfecting the u s e of the electric-eye control and t o show the u t i l i t y of the unit as a part of general foundry production equipment. In these studies i t was found possible t o blow iron from a cupola, with widely variant analyses, t o a remarkably close end point of 0.07% C and 0.07% Si by use of the electric eye. Metal made in this manner w a s converted into steel by the addition of suitable alloys or by the addition of cupola iron and t h e requisite alloys. Composition control of carbon 2097
Pouring steel from an induction furnace in the metals laboratory
was found to be quite precise and addition efficiencies were quite high. There was also good control in the making of hightest or malleable iron compositions with high efficiency of alloy additions. Blowing losses, other than the loss of carbon, manganese, and silicon, were reduced to below 5 % and further reduction seems possible. I t appears that the side-blow converter may have more merit than is generally appreciated. Steel Casting. Research on steel casting, which has been in progress during the past three years under the sponsorship of American Steel Foundries, has continued. The process has been improved and refined during the year just completed. Wear-Resistant Cast Iron. An investigation related to the manufacture and control of an abrasion-resistant cast iron for a particular application has been undertaken. This program contemplated the correlation of laboratory wear tests as well as actual service performance with manufacturing methods, chemical analysis, and microstructure. Welding. Research for the Rail Steel Bar Association on methods for welding rail steel has continued through the year. Attention has been centered principally on the metal arc-welding process. When welding plain high carbon steels, such as rail steels, it is customary to use both preheating and postheating treatments auxiliary to the operation. However, the present objective has been to determine the maximum weld quality obtainable without these auxiliary heat treatments. •Improved welding procedure and technique have been developed. Ultimate weld strength, when tested transverse to the weld, has ranged consistently around 100,000 psi for butt welds in 0,375-inch flats and higher for thinner sections. Over-all welding ductilities and tensile strengths are equal to those of the rail steel itself in the lower carbon ranges, but have been limited in the higher carbon ranges by the lower strength of the deposit metal. Wire Drawing. The National-Standard Co. is beginning the fourth year in sponsoring research on fine wire and fine wire drawing. Recent diamond die studies on 2098
the nature of wear, die design, and statistical data have provided a reliable means of evaluating diamond dies. Several die manufacturers have accepted the methods of inspection and standards of diamond die design as developed from this work. A diamond die recutting machine has been developed which resizes the dies efficiently and accurately. A wire drawing lubricant has been developed and is now being used in the regular production machines. Physics Research
U. S. Navy. Several projects have been in progress during the past year for the Bureau of Ships and Bureau of Ordnance of the U. S. Navy. Although this research has constituted a large portion of the work in physics, for reasons of war security it is not possible to report upon it at this time. Through the cooperation of sponsors who have agreed to discontinue temporarily their work on peacetime programs, and with the aid of many foundation facilities, it has been possible to achieve quick development of several devices which have contributed materially to the Allied war program. Office of Scientific Research and Development. The work for the OSRD has continued during the past year, with one new contract being added. Several new electromechanical devices have been developed, and extensive field tests have been conducted. The work has been materially aided bj^ the fine cooperation of the U. S. Naval Air Base, Glenview, 111. As with the Navy work, in order to complete these OSRD programs as quickly as possible it has been necessary to discontinue the work on several peacetime projects which are being held in abeyance for postwar research. Abrasives. A project conducted during the year under the sponsorship of the OPRD, and continuing as a fundamental study, is a further^ extension of the foundation's investigations of the properties and reactions of matter under extreme pressures and temperatures. Concerned a t present with the synthesis of heavy-duty abrasives, this work involves new techC H E M I C A L
niques and pressures of several million pounds per square inch. Gas Containers. During the past year, investigations have been completed on certain phases of a research project designed to obtain improved service from commercial gas cjdinders. Lithography. The Lithographic Technical Foundation has established an extensive research program at the Armour Research Foundation, intended to improve lithographic processes and to find new applications of lithography to the graphic arts industry. The program will supplement the research activities which the Lithographic Technical Foundation has been conducting for about 20 years. This arrangement means t h a t many of the major research projects for the Lithographic Foundation will be carried on here, investigations will include studies of photographic reproduction, plate making, improved blankets, ink control, paper, presses, and health hazards. Such a broad program will necessarily require the cooperation of research men from many scientific fields; hence it is expected that the physics, metallurgy, chemistry, and engineering mechanics sections of the foundation will each undertake certain major phases of the program. Mica. The importance of increasing the production of domestic mica became apparent at the outbreak of the present war, when this country was almost totally dependent upon India for mica of condenser quality. The Armour Research Foundation had a part in the research investigations which were set up by the WPB about two years ago with a view to improving methods of inspection and fabrication of mica. During the past year, research on mica for the WPB has been continued. The purpose of the present investigation is to study the possibility of improving certain visually defective domestic mica to render it suitable for use in electrical condensers. * Noise Reduction. Fluid flow studies have continued toward determination of the mechanism whereby noise and cavitation are produced as liquids flow around bends in pipes and through small orifices. Using information obtained from highspeed motion picture studies and from visual observations through transparent windows, experimental orifices and valves have been designed which, for a given head and pressure drop, show a marked reduction in noise. Turntables. The reduction of speed variation and noise in electric phonographs is the object of a project sponsored by the General Industries Co., Elyria, Ohio. Stroboscopic methods have been used to measure speed variations in the elements of the turntable drive, and research is in progress on methods for improving the turntable speed regulation. Measurements have been made of the motor vibration transmitted to the pickup, as an aid to studying the effectiveness of more accurate dynamic balancing of the motors and better vibration isolation between motor and pickup. Watch Technology. Studies in the field of watch technology have been confined during the past year to the development of methods whereby many machining operations may be eliminated from the production of watch parts. The severe precision requirements of the watchmaking industry make necessary a very complete control over any process appfied to such production. Special Studies. In addition to the longterm programs, during the year the Physics Section has aided numerous manufacturers •by carrying out a wide assortment of shortterm investigations. These have included A N D
E N G I N E E R I N G
NEWS
comparison of sound-level meters, soundlevel measurements of warning signals, oscillographic studies of electrical transients, high-voltage insulation tests, resistance measurements of platinum wire, electrical conductivity tests on flooring materials, determination of electromagnetic radiation from small motors, and a variety of measurements on magnetic materials. Most of these studies have been made to determine compliance with Army and Navy specifications. The Physics Section's rather complete x-ray diffraction and spectrograph^ laboratories have aided materially in the solution of many problems in chemistry, metallurgy, and mechanics. Valuable contributions of this kind have also been made where special optical or photographic techniques have been required. The laboratory is well equipped to make studies involving light transmission, spectrophotometry, colorimetry, and microscopy. Several specialized photographic techniques are often applicable to the solution of various research problems. The Optics Laboratory has made valuable contributions through the use of its facilities for high-speed motion picture and multifiash photography, photomicrography, and stereoscopic photography. Engineering Mechanics Research
Air Conditioning. A study is being made of different t3rpes of cooling systems applicable to special forms of air-conditioning equipment. Airport Runways. The research on impact loading of airport paving for the Civil Aeronautics Administration is drawing to a close. This work has involved the determination of static and dynamic loads imposed on airport runway surfaces. Methods of instrumentation have been developed for measuring the total force and the distribution of pressure on the tire contact areas. Automatic Sprinkler Control. A program having as its objective the improvement of the hydraulic jet air pump and valves controlling the operation of an automatic sprinkler system has been carried out for the Automatic Sprinkler Co. of America. A new type valve control making use of permanent magnets has been developed. The efficiency of the hydraulic jet air pump has been increased to several times its original value by means·of a new nozzle design. Bolts. Under sponsorship of the Navy's Bureau of Ships the Armour Research Foundation is investigating the shock strength of bolts and fastenings. This study is being carried out on the Navy high impact shock stand. Bushings. Fatigue testing of metallic parts of a tank track has helped to make possible improvements in the design of the binocular type linkage. This phase of the work on tank track treads has drawn to a close and a new program is in progress on collecting design data for rubber bushings for track usage. The Burgess-Norton Manufacturing Co. is sponsoring this project. Copper Welding. A program for the development of a satisfactory method for achieving certain special-purpose copperwelding operations is being conducted for an electrical motor manufacturer. Core Boring. A method has been developed for removing undisturbed cores from soil-stabilized materials. The method allows the removal of these cores even when a very hard flint or chert is present in large quantities. This program was sponsored by the Civil Aeronautics Administration. Crane Survey. The crane survey project V O L U M E
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sponsored by Whiting Corp. still continues. Engine Couplings. The Auburn Manufacturing Co. is sponsoring a program on internal combustion engine couplings. Theoretical analyses and experimental data are being combined to obtain a large range of design information for various couplings. Flexible Shafting. Work is being carried out in the engineering laboratories on an investigation of the performance of flexible shafting. Also, theoretical considerations are under study in an attempt to systematize design and application of this type of shafting. The program is sponsored by Stow Manufacturing Co. Fountain Pens. This project has as its initial aim the study of capillarity with respect to the performance of the communicating channels in the writing and filling operations of a fountain pen. Subsequent effort has been directed toward employing novel arrangements of capillaries to enhance the performance of the Parker " 5 1 " pen with respect to writing, filling, and external leakage elimination. Gas Turbine Blades. A research project initiated by the OPRD concerns the gas turbine, which promises to become an important prime mover in industry. One of the serious drawbacks in this development has been the high temperature at which the turbine blades must operate for maximum efficiency. The present project centers on a porous blade fabricated from powdered metals, with an attempt to determine whether such a blade can be cooled by liquids or gases while in operation. Gear Wear. The program on wear in gears, sponsored by the Whiting Corp., has been concluded and the findings of this investigation have been reported. Glass Fibers. A project having as its objective the improvement of fiber-forming processes is in progress for the OwensCorning Fiberglas Corp. This program is essentially of a theoretical nature and the results are intended for use in working out better shop practices in the manufacture of glass fibers. Insecticide Dispensers. The BurgessNorton Manufacturing Co. is sponsoring a program for the development of a unit for dispensing insecticide fluid under pressure.
DECEMBER
Pumps. A project for the development of hydraulic and pneumatic pumps and motors of a positive displacement type and a mechanism of radically new principle is being conducted for the Pittsburgh Equitable Meter Co. This is a very comprehensive program requiring the development of an adequate theory to explain the operation of the mechanism, a complete investigation by experimental means of the performance of existing models, and formulation of recommendations leading to improvements in the design. Shade Rollers. The program sponsored by the Western Shade Cloth Co., involving the development of shade roller mechanisms, has been completed. Several new types of mechanisms have been developed. Vacuum Tubes. The electronics division of the engineering mechanics section» has been engaged in a study of the effect of shock and vibration on. vacuum tubes, under the sponsorship of the Navy Department, Bureau of Ships. Wire Rope. The wire rope investigation for Whiting Corp. has been brought to a successful conclusion with the discovery of new design criteria. A comprehensive study of the experimental data contained in foreign and domestic technical publications, supplemented by tests conducted on a large fatigue machine, have shown that bearing stress is far more significant than the bending or direct tension. Plans have been approved by Whiting Corp. for the release of this information in a technical, publication. Wood. The Weyerhaeuser Timber Co. is carrying on a program involving analysis of the variability of wood properties and establishment of improved methods of lumber evaluation. The ultimate aim is to so grade lumber that each, grade will be directed to that use where its performance relative to cost will be most satisfactory and economical to the ultimate consumer. Shock Testing. The Navy light-weight shock testing program for electrical equipment has continued on an expanded scale. The following companies are members of the cooperative group who have contributed to the cost of these facilities and are making use of them:
Studying viscosity of molten glass
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1944
2099
Lumber strength investigation
American Electric Alotor
