Document 3eG3kNRdEZa64yd3E97ovm6RD

jrse THE VOICE OF AN INDUSTRY For at least ten years, certain conser vationists. and. more recently, en vironmental groups have been bringing pressure on governmental authorities to ban the use of lead shot in waterfowl hunting. Their reasoning is that some waterfowl, ducks and geese, feed on marsh bottoms and ingest lead shot as well as grit in heavily hunted areas. Subsequently, death is caused by lead poisoning. Estimates have run as high as three million deaths per year. How ever. the fact remains that the very limited amount of work done in the area does not justify any estimate, let alone three million deaths annually. Manufacturers and researchers have been seeking a suitable substitute shot material for several years, and for a while, soft iron shot seemed to be emerg ing as the most viable product. It now appears, however, that this product may well cause more problems than lead shot. Exhaustive tests conducted by a John A. Mardick Vice President -- Metals Division NL Industries Inc. Director, Lead Industries Association, Inc. major ammunition manufacturer see to rule out soft iron. These tests ue conducted over an eight-month peri at a midwestern facility designed fort purpose, and a careful analysts of i huge volume of data leads to the co elusion that soft iron shot will kill more birds from crippling losses than it > claimed now for deaths due to lead i poisoning. The simple reason for that is that iron, being much lighter in, weight than lead, is not lethal at the average shooting distances from which t most waterfowl hunters fire at birds.; Copper also was found to be too light ( ballistically, and could also be toxic. The lead shot market is important toour industry. Therefore, the L.I.A. as well as the individual lead produceis* should actively seek to prevent the bath ning of lead shot unless or until a highj incidence of lead poisoning of waterfo*! is conclusively proved. 2 L IA 2 6678 H** \)SZ 'TWEETER* LOUDSPEAKERS LEAD ZIRCONATE-TITANATE W|u|e numerous people enjoy high (i,ieiitv music, they may be un,1 t tJle majority of high hdelity '"'"j nails consist of at least two j -noofer". for low and me- Hinds; and a "tweeter", for 11 ''M,itch notes. Different from each 'm function and design, each :,K, ,r jui. its own design requirements, d"oii'ciitional tweeter speaker in a ,R|i.[ih si stem uses a mechanical T" 1|Kj niuunet arrangement which rt- electric energy to reproduce the .(,.,,i'r!ied notes. By using lead eate-titanate t PZT i. engineers at \( tonda's Piezoelectric Products Divi- franklin Park. Illinois, have con ned this mechanical operation to an i tr,,.mechanical operation and are piducina the company's most efficient I'/T tweeters to date. in the tweeter because the material ex pands when subjected to an electrical \ ullage and then contracts to its original shape when the voltage is removed. All this action takes place in timed, micro second sequences. Because of piezoelec tricity, Motorola engineers were able to provide a permanent, built-in. drive capability for the cone. The Motorola driver disc consists of two \erv thin, wafer-like PZT sections separated by a corrugated brass spacer which supports and joins them. The driver is activated by a high-frequency electrical signal on one side of the disc, thus causing the PZT section on that side to assume a convex shape. This action simultaneously forces the center core and opposite PZT section into the same shape. All three components return to their original shape when the elec- tinuouslv at peak power without failure. The new tweeter is the most efficient of Motorola's four previous PZT tweet ers. From oniv 1 volts input, the speaker w ill generate 98 db > decibels i sound pressure on a microphone placed 18 in. awav. The frequency respunse of the tweeter is from 3.150 cycles to 21.1100 cycles per second, the range desired by the audio system designers. The high precision PZT ceramic discs for the drivers are ground to close toler ances from rods approximately 0.89 in. in diameter and 1.5 in. long. The mate rial is carefully selected for its electrical properties (dielectric constant is 3 100 and the electro-mechanical coupling fac tor is 0.63 l. The rods are cut into discs that are 0.0055 in. thick and vary in thickness only a few ten thousandths of an inch. Nickel electrodes are plated to an ri al he lie is his in the dell i'ds. i glit t to . as cers banhigh fowl ielt--Enlarged cut-away view of PZT Oise and, Pignt--Tweeter speaker $rcwmg position of PZT disc. At left, view A and 8 shows PZT discs with corrugated center vane and at right, view C (top) shows completed ceramic disc assembly and (bottom) cut-away view of completed assembly. The use of PZT allows the engineers to design tweeters w ith a built-in ability to reproduce high-pitched notes. Through a unique property shown by this ceramic material--known as piezoelectricity-- electrical impulses are converted directly into vibrations, PZT discs thus become the power source to vibrate the tweeter cone, the flexible device at the front of a speaker that produces the sound. To accomplish this, lead zirconatetitanate ''driver'' discs take the electrical signals from the amplifier and translate them into very rapid vibrations ranging from 3 to 20 thousand cycles per second. The discs are connected to the point of a small paper cone which, being much larger, is able to efficiently transmit the multi-thousands-per-second airborne vibrations to the air, thus forming the high-frequency sound waves. PZT works trical signal is removed. The process is repeated as the electrical signal is ap plied to the opposite PZT disc. The alternating application of elec trical signals to either side of the driver rauses it to vibrate against the paper cone as many times per second as de sired--up to 20,000 times per second. Motorola engineers speak of PZT as an "ideal" driver material. According to Hugo Schafft, Manager, Piezoceramic Products, Motorola, Inc. lead zirconate-titanate "is found to be an almost ideal driver material for highfrequency, high-fidelity speakers" be cause it contributes significantly to the following characteristics of a superior tweeter; simplicity of design; high effi ciency I,up to 15 times higher than that of comparable dynamic speaxers); low weight; and the capacity to operate con- each disc, and a pair of discs is assem bled with the corrugated brass spacer between them. This construction, utilizing; the piezo electric properties of lead zirconatetitanate has an efficiency (energy con version factor) of 31 per cent, much greater than that of all but the best high-frequency loudspeakers. Although piezoelectric materials have been known to scientists since Pierre Curie investigated them in the late 19th century, they did not have many prac tical uses until the late 1930's. During WWII, piezoelectrics were used in sonar i to "listen" for other ships i and in other electronic systems. It was not until the 1950's that lead zirconate-titanate received serious attention, primarily as a spark source similar to spark plugs. POSTAL SERVICE PLUGGING INTO ELECTRIC MAIL DELIVERY Hi 9i?lf Otis Eiectric Delivery Vehicle, built by Otis Elevator Company plant at Stockton Calif., is being tested at Santa Ana, Calif. The more than 100.000 internal com bustion engine-powered l .S. Postal Service mail delivery trucks may even tually be replaced by fleets of electrics at a rate of 5.0(H) vehicles per year. That's what could happen if tests now being conducted in the Eastern l nited States and in California prove that lead acid battery-powered vehicles can deliver the mails more quietly, efficiently, and with far less energy consumption than internal combustion-powered vehicles. One L.5. Postal Service official estimates that the initial vehicle replacement pro gram would begin with about 3.300 elec tric vehicles per year and then, as pro duction facilities expand--and provid ing the electric vehicles continue proving themselves--the replacement rate could increase to about 5.000 electrics per year. As an indication of the U.S. Postal Service's serious interest in evaluating the electric postal delivery van concept, it is funding tests of such vehicles in Cupertino, near San Jose in Northern California: in Santa Ana. near Los An geles in Southern California; in the East ern U.S. at Allentown and Bethlehem, Pennsylvania; and in Low-ell. Massachu setts, near Boston. 1 nlikc the internal combustion vehicle it replaces- the electric truck is. accord ing to V, etherhold. "very comfortable to handle and drive". He adds that the vehicle is smooth operating and the ab sence of a hot engine results in a much cooler cab in which to drive. Allentown's Postal Supervisor Rich ard Troxell says the significant factor, in addition to its being pollution free, is the fact that the battery-powered car rier may cost less to operate. The electric mail carrier being tested at Allentown is manufactured bv Battronic Truck Corp., Boyertown, Pa., the nation's leading producer of electric ve hicles. Battronic also is producing 100 on-the-road electric vehicles as part of a million-dollar nationwide testing pro gram funded by 55 electric utilities un der the sponsorship of the Electric Ve hicle Council IEVC). The vehicle Battronic is supplvin,, j the Allentown test is powered by a ^ volt lead arid battery and it has a p speed of IT mph. Plans call for te-tj/ the vehicle on a variety of routes i n Al. lweniltlohwen..asfkaedrrietorsraotepeirtsatipnegrf.otrhrmue` ance at the end if the te-t period. As part of the test program, three more battery-powered electric vehicle, are scheduled to be tested at Allentown Three similar vehicles are slated to f,t tested at nearby Bethlehem. Pa. Meanwhile, in Cupertino, Calif.. a(j jacent to San Jose, plans are being made for full-scale electrification of the town', mail delivery service a- the result of a two-vear test of electric vehicles f,Vr mtra-city mail delivery. Thirty electric vehicles, also powered with lead acid batteries, are slated to replace the stan dard internal combustion vehicles that comprise Cupertino's present mail deliverv fleet. Cupertino Postmaster Alvin R. Carter claims that the trucks are smog-free and cost only about one-tenth as much as the conventional tvpe to operate. The electrics can operate for at least two davs without recharging the batteries. When a recharge is necessary, it is accom plished with an industrial-tvpe charger. The trucks have a top speed of 40 mph on a two percent upgrade and are powered by two. 146-volt, lead acid bat teries. However, they will travel at a maximum of 35 mph to conform with Cupertino speed laws. The almost silent vehicles produce only a slight hum as thev accelerate, in- The tests are already underw ay at Cu pertino, Santa Ana and Allentown and they are slated to begin very shortly at Bethlehem and Lowell. As part of the tests, Allentown, Pa., letter carrier Frank Wetherhold is piloting a new, all-electric, lead acid battery-powered truck to de liver the mail in the city's 14th Ward. Battronic Truck Corp., Boyertown, Pa., built vehicle being tested at Bethlehem and Allentown, Pa. LIA26680 4 ence Laboratories, an independent test >r ing facility located in Phoenix, Ariz.. if, and the company says it meets all specifi cations set forth by the U.5. Postal Ser vice under its Electric Vehicle Program. M. Called the Otis Electric Delivery Ve it hicle, the van can travel a distance of about 40 miles on a single charge and it has a maximum speed of 43 mph. Six teen 6-volt lead acid batteries power the n vehicle. Since the middle of June, the Otis vehicle has been driven on regular mail routes in the Santa Ana area. Hector Godinez, postmaster of Santa Ana and sectional Center Manager of the Orange County Postal Department, sees the ve hicle as the forerunner of the type of -iirins quiet early-morning deliveries. are ideal because they are not too hilly vehicle that will eventually be used on \nd since they draw power only when and, in addition, their warm climate is all routes in Orange County, Of the n- (he vehicle is in motion, the cost and pol- suitable for year-round electric vehicle 1.500 routes in the Countv. 1.300 re !udon of an idling engine is eliminated. operation. quire vehicles to distribute mail. er he The test vehicle has now been in oper ation at Cupertino for a little over a year and it has been utilized on the same routes as the regular Post Office vehicles. The length of these loutes ranges from S to 15 miles w ith 100 to 300 stops. in addition to the vehicles Battronic Truck Corp. is supplying for the Allen town and Bethlehem tests. Transporta tion Systems Laboratory is supplying the vehicle for the Lowell tests. In Cali fornia, a combination L.S.-British ve hicle will be used for the 30 prototypes The tests at Lowell. Mass., began in late September, An electric delivery van produced by the Transportation Systems Laboratory, a Division of Elec tromotion, Inc., Bedford. Mass., is being used for the project. vs <n n r. 10 During the tests in Cupertino, daily mileage, power consumption, the num ber of stops and general maintenance readinss have been recorded. In order to rive these data some sort of perspective, for the Cupertino "ElectroMail" proj ect. Harbilt Electric Vehicle Co., Man chester, England, built the vehicle's electric propulsion system and the ve hicle was completed by Electric Vehicles, The five-city electric vehicle mail de livery project is being funded by a L.S. Postal Service program. It is designed to test various tvpes of vehicles under various conditions, and to determine the it- a th a control vehicle was selected at random -a jeep powered by a four cylinder, in ternal combustion engine--and compar ative data were recorded. The overall re Inc.. San Francisco, Calif. The vehicle being tested in Santa Ana is designed and manufactured in the Stockton, Calif.. Special Vehicle Plant ability of manufacturers to produce electric powered vehicles that will meet the L.S. Postal Service's need. It is ex pected that, in time, a standard L.S. ce ! n- sults of the battery versus internal com bustion-powered vehicles study proved that four mail delivery vans powered by cf the Otis Elevator Company. The ve hicle has been tested by Dynamic Sci Postal Service electric mail truck will be developed. lead acid batteries could be operated for the cost of operating one internal com J bustion vehicle. Reaction to the vehicles by Cupertino postal carriers who operate them is gen erally favorable. One carrier commented that she feels better at the end of the day because the electrics minimize vi bration or noise. Don P. Crane, Director, Office of Fleet Management at postal headquarters in Washington, D.C., feels that if the 30 'ohicles are successful, this may lead to their introduction in several other ``sun hdt ' cities such as Phoenix, Miami, Memphis and Los Angeles. These cities Harbilt Electric Vehicle Co., Manchester, England, and Electric Vehicles, Inc., San Francisco. Ca/;7., have learned up to build 30 vans being fesfetf at Cupertino, CalH. LUZbbbl SUBMERSIBLE WORKBOATS, NEW OFFSHORE INDUSTRY WORK TOOL OI cean exploration reached new can operate at depths up to 5.600 ft. lighting, instrumentation and life-sup heights during the 1960's when a In addition, HYCO also has developed port systems must be self-contained. And variety of small, manned submersibles a number of undersea work platforms since lead acid batteries are the most were developed to probe the depths of and surface "mother ships'' that supply reliable power source for satisfying these the world's oceans. undersea vessels and work platforms. requirements. HYCO's submersibles are Todays submersibles, literally minia ture submarines, offer tremendous poten tial to unlock the vast undersea ware house that will provide future supplies of food, oil. gas and minerals. They can dive deep and remain on station longer than a suited, helmeted diver and, more important, they can be fitted with all kinds of equipment for specific functions. International Hydrodynamics Com pany. Ltd. iHACOt. North Vancouver, B.C., is Canada's major manufacturer HACO's offshore industry projects have included subsea pipeline route surveys, research exploration programs involving wellhead work, and core sampling. The value of the company's submersibles as effective research ves sels has been demonstrated on a number of occasions. Twice they have been em ployed for research that included ob servation of fish behavior and the mapping of herring spawning grounds. powered by a series of such batteries. The company's submersible batterypowered systems range from 225 to 150 amp. hrs. at 120 volts. Primary batteries for the submersibles are a 60 cell. 120 volt DC system. The secondary, or back up system, is 28 to 12 volts. Recharging these batteries after each dive takes ap proximately six to eight hours. According to James McFarlane. HA CO vice-president of engineering, of submersibles and is one of North Because these craft must remain be lead acid batteries were specified for America's leading producers of such neath the surface for extended periods the submersibles because they offered vessels. The company manufactures a of time without assistance from a mother ease of maintenance, ready availability, series of maneuverable submarines that ship, all internal power sources such as and lower cost than other batteries. i AD-L-INED p r e c ipit a t o r s t u r n POLLUTION INTO PROFIT The Xoranda Company, a leading Ca nadian metals and mining producer, has turned a potentially serious air pol lution problem at its Gaspe Copper Mine into a profitable emission control operalion. It produces a commercially valu able chemical, sulfuric acid (LLS04), in such volume--300,000 tons per year --that a special ship has been built to transport it to market. The potentially serious air pollution problem resulted from an expansion pro gram at the company's copper mine that 'ould double its copper in concentrate production to 70.000 tons annually and mirease the copper smelting capacity by -.000 tons. The sulfuric acid is pro duced from sulfurous oxide gas (SO-) Tat is generated in vast amounts durlns the final phase of leaching copper unm copper concentrates, if released un treated into the atmosphere, the SO-'as. which is highly corrosive, would ta'e damaged the environment. To control the SO- emissions and eliminate their potential environmental problems, Xoranda installed special l,rcessing equipment called acid mist precipitators to convert gas to sulfuric acid. Because the interior walls and op erating components of the precipitator were to be constantly subjected to the highly corrosive SO- while being con certed to sulfuric acid, which also is highly corrosive, it was absolutely neces sary that they be fabricated with ma terials that could take the severe service conditions inside the precipitators. Lead, being a particularly corrosionresistant material, was specified for the interior walls of the precipitator as well as the tubes through which the gas and mist pass while being subjected to strong electrostatic charges that create particles of sulfuric acid mist. The mist condenses and turns into droplets that collect on the interior w alls of the precipitator and the tubing. Just as condensation on win dows eventually becomes so heavy with moisture that small rivulets of water run down the window, so, too, do rivulets of sulfuric acid run to the bottom of the precipitator where they are collected. In all, 250 tons of lead were required to construct the Gaspe Copper Mine pre cipitators. Each precipitator is a 75 ft. high, 19 ft. diameter two-stage unit. It consists of nearly 1.130 extruded lead tubes, each 15 ft. long. Of the total, 1,101 of the tubes were 10 in. diameter and 21 were 13 in. diameter. All the ex truded tubes had 10 psf. i. 1563-in. thick) sheet lead walls and the walls of the three banks of enclosures were lined with the same thickness of sheet lead. A thousand-ton lead extrusion press was shipped to the installation site to extrude the tubes rather than risking their being damaged or delayed in de livery while being transported for long distances over winter-ravaged roads leading to the Gaspe Copper Mine. While some of the sulfuric acid processed at the Gaspe Copper Mine will be used for the mine's own ore leaching process, most of it will be loaded aboard the Silverpelerin, a 7500-ton. 35 million ocean-going sulfuric acid tanker built especially to transport the chemical from Gaspe to the Pfizer Company's plant at Xew London, Conn.; and Allied Chemi cal's plant at Baltimore, Md. LIA26683 7 ultimate in executive jet I travel" is the phrase commonly used by passengers and pilots alike in describing Grumman Corporation's new business jet, the Gulfstream II (G-II). This sleek-stvled aircraft, available with custom designed interiors, also possesses another significant feature--it is re ported by the manufacturer to have the quietest interior of all corporate jets. Powered by two turbofan engines that provide a maximum speed of nearly 600 mph. the G-II encounters high intensity aerodynamic noise, also known as boun dary layer noise. Aerodynamic noise in creases with velocity, and this in turn creates a continual excitation of the fuselage skin. Depending on the air craft's speed and shape, such boundary leaded vinyl (lead powder dispersed in layer noise can cause extremely high vinyl), is sandwiched between two lay noise inside the craft. ers of compressed acoustical foam and The combined effect of the boundary is secured in place by the cabin head layer noise and that of the powerful tur liner. This installation technique elimi bofan engines created an overall noise nates the need for fasteners which would level of 110 decibels in the untreated have penetrated the leaded vinyl and cabin. This uncomfortable sound level, provided a large number of routes for which can be detrimental to hearing, noise to enter the cabin. Another major compares to the noise of a jet fighter advantage of using leaded vinyl in this at 1000 It. form is that it is virtually free-floating, Despite this high exterior noise level, thereby improving its effectiveness as a Grumman specifications called for a sound barrier. cabin interior that was "living room The weight of the leaded vinyl was quiet." The company's engineers there increased for forward sections of the fore were faced with the task of de aircraft because these areas are sub veloping a sound control system to over jected to higher noise levels of boun come noise problems common to all jet dary layer noise at maximum cruise aircraft. speeds and, in addition, the glass en Grumman's G-II sound control sys closed cockpit is more susceptible to tem incorporates three essential ele noise penetration. Three weights of ments: (I) a barrier between the craft's leaded vinyl were used--1.5 psf for the engines and the cabin interior to block cockpit, 0.57 psf for the forward section the path of exterior sound; (2) methods of the cabin, and 0.28 psf for the mid to damp interior structure borne sound and rear sections of the cabin. radiation and isolate engine vibration; In the first of the two other sound (3) a method to absorb sound inside control system elements, damping foam the cabin and prevent its reverberation. was used to reduce interior structure- Because the sound barrier between borne noise while additional external the exterior skin and the cabin interior noise reduction resulting from engine headliner was the most critical element vibration was achieved through the use in the total sound system, the engineers of low density fiberglass. The third ele selected a multi-material system incor ment, interior sound absorption, is ac porating lead, the most efficient sound complished through the use of such cus barrier known. The sound barrier, tom designed and installed furnishings 8 as thick pile carpet, fabric upholsters! chairs and sofas, and ear-level, softfabric curtains near passenger seats. The effectiveness of the G-II sound control system is documented bv the fact that the 110 decibel level of the untreated cabin interior is reduced to the 55 to 60 decibel range. (These are sound levels at which a normal voice can be heard at 10 ft. I Such souod levels are much lower than other com mercial aircraft and, according to Grum man. they are among the lowest for any jet aircraft. This, says the company, ii due in part to the astute use of lead in the aircraft's sound control system. L IA 2664 300 mp h t e s t t r a in r id e s o n a ir ()t be too long before you will Because the present vehicle is pri two sources--turbofan engine noise and 1 tlvinu Buck Rogers style just marily designed to test the TACRV's boundary layer noise such as that en ,l p around on a magic carpet of jit,L)Ujt*L,f-JSlOhOiiz'mh-ppshpeesdpeetdrasino.n board Such a a new train, major components -- the air cushions, suspension systems and an electric pro pulsion system--seating has only been countered by the G-II. Since economics was a consideration in the design program, existing aircraft bv Grumman Aerospace Corpora- provided lor the operator, test instru hardware and design technology was \U inJ called a tracked air cushion re- mentation engineers and technicians. used. The vehicle's windshield is the ::t" p, vehicle iTACRVi. is now being Therefore, only the TACRV cabin had same as the one used for the Gulfstream " 'ted as part of a U.5. Department of to be insulated against sound. ii. its air conditioning system is the `Pfn-pcrtation plan to develop high- To insulate the cabin, the multi same as that used for commercial air d railroad vehicles that will provide material noise insulation system was ap craft, and high strength surplus seat jjds-i-,,n,g,,.tr` and carszo service between lirban areas. Phe research vehicle, which looks like plied in the same manner as the system installed in the Gulfstream II: damping foam was applied to about 50 per cent frames from a B-52 bomber were reup holstered to provide modern-looking passenger seats. j \\ iHnIuS.les~s- aircraft that flies at t-ground l^jel alona an electrified roadbed, is de of the skin area, a 4-in. thickness of low densitv fiberglass was compressed The TACRV is currently being tested at the Department of Transportation's ed to have a maximum speed of 300 into the 3-in. depth between the frame new high speed transportation track mph hen it is electrically propelled by bnear induction motors that will be caps and a 1 psf leaded vinyl sand wiched between two Vo-in. thicknesses which is being built near Pueblo, Col orado. A mile and a half track, the te-teci as Part the research program. of polyurethane foam was installed over first increment of a 22-mile test oval However, for present test purposes, the the fiberglass before the cabin lining to be built at the facility, is being used tracked air cushion vehicle concept is w as installed. In addition, a 1 psf leaded for the first phase of the test. beina evaluated by utilizing three turbo vinyl curtain was suspended behind the During the initial testing, the three fan engines, mounted in a streamlined aft cockpit bulkhead to provide addi turbofan engines will provide com Tf-d oft- pod atop the rear of the vehicle, to .apply power for the cushion of air on i,huh the vehicle rides and the thrust tional insulation from the noise of the rear-mounted turbofans. The noise insulation is providing the pressed air for the TACRV's air cushion system and power to propel the vehicle. During later phases, the much quieter to propel it up to 123 mph speeds. research vehicle operator and test en linear induction motor, which will utilize und Though different in design and func gineers with a quiet environment for all wayside power built into the track, will the tion. the TACRV faced the same prob- phases of the test program. During the propel the vehicle while the turbofan the rms as that of the Gulfstream II I G-1I) present phase when the vehicle is being engines will supply only the power for to business jet--turbofan engine noise and tested for speeds of up to 125 mph, the air cushions. arc aerodynamic-related engine noise I,the noise protection from the turbofan jets 1-11 at 600 mph at 35.000 ft. has al is a primary consideration. Later, when und most the same free-stream dynamic the second phase of the tests is under i *m- pressure as the TACRV at 300 mph at way and the linear induction motor is um- rea level). However, Grumman engineers used to achieve the vehicle's an v had a distinct advantage in designing maximum 300 mph . i> the TACRV since they had already de speeds, noise in signed the highly effective sound control will come^ system for the G-II. Based on this previ ous experience and knowledge gained in developing the sound control system, it was easily incorporated into the research vehicle 9 BATTERIES PROVIDE UNINTERRUPTIBLE POWER TO BACK-UP IBM'S OWN COMPUTERS International Business Machines l IBM). a firm believer in its own products, relies heavily on its vast network of na tionwide computers to conduct the com pany's dailv operations. The company uses IBM computers to communicate The decision led to the installation of a battery-powered UPS system, provid ing the computer system with the additional advantages of protection against transient disturbances and from short term power outages that could range up data to and from its 358 manufacturing to 30 minutes in duration. plants, branch offices and education cen ters. All this requires 36.000 miles of leased telephone lines. 1.200 TV-like Administrative control center at White Plains, N.Y. connects IBM headquarters with company's U.S. offices. Lead-calcium batteries were selected by the designers because of their lung life and minimum amount of main IBM computer terminals and 5.000 com tenance requirements. There are three puter communications technicians. lead-calcium batteries with 177 cells in IBM's own computer headquarters is each bank, for a total of 531 cells. Each housed at the company's 'Shite Plains, cell is a battery itself weighing 340 _\.Y. Data Processing Division. Any lb. Total weight is 90 tons. Voltage per power loss would interrupt the large cell ranges from 1.8 to 2.25 supplying amounts of data constantly being pro 1950 amp hours, an eight-hour capacity. cessed by the computers, so IBM has The battery-operated installation was installed a power back-up system that designed to provide power for thirty uses 531 lead-calcium batteries--total minutes. This not only provides power weight 90 tons--to assure a dependable to run the headquarter's computer sys emergency power source. tem for the short time it could take to When it came to choosing the back regain regular electrical power, but it up power system for the relatively new also provides power to shut down the computer complex, called the Advanced system if it is determined that a lengthy Administrative System, IBM engineers power loss is expected. Unlike an elec worked with outside consultants from tric light that can be turned on and oS organizations familiar with uninter without harm, a computer installation ii ruptible power systems (called UPS). One of the first decisions made by these such as the one at IBM headquarters must be shut off in a series of timed, experts was in favor of a system that pre-determined sequences to insure that would provide back-up power for an none of the equipment or data it con orderly shutdown and maintenance of tains is damaged. the installation's data for a finite pe The UPS system is rated at 1250 riod in the event of a power shortage KVA (enough electricity to provide or outage. This was considered prefer power for a large industrial building! able to attempts to keep a system going at 0.8 power factor ipf) which consists for a prolonged period of time through of 6 inverters, each rated at 250 K\A- complexities of back-up power supplied by generators. IBM maintenance engineer checks one of the 531 emergency power lead-calcium batteries. The system also includes three 500 rectifiers. LEADED s t a in e d g l a s s s a t is f y in g pEMAND FOR THE HAND-MADE LOOK I*n todav's computerized, automated, as-emblv line society. machine; can pro! ,ce in an hour the amount ot quilting j. U(>i;!d take an imli\ iclual weeks to pro- bv hand. Mu.-eum pieces are repromeed in pla.-ter and synthetic diamonds ire even being worn by the jet set. but some ot this is producing a back up. Mane people are beginning to want i.jsh quality possessions made with authentic materials, and they are put[;rlg greater and greater premium on the work of individual craftsmen who .,,jL;e something themselves with their lr,v men hands, rather than a machinemade replica from imitation material. for example, there is renewed inter.in hand-crafted lead -tained glass but it- resulting in main hange- of at titude regarding where and how stained class can he used. Now regarded as a . ,,ritemp"rarv art form, it is rapidly ex' ..Hiding trom its traditional uses as digiviis theme window- to perfumi burtul and -onietimes dramatic uses .is decor itw iv-iaurant-. -tores, office buildings, homes and apartments. The demand lor stained glass used to Irimrate homes and apartments is re-ulting in the pre-erxation of some of the nation's most noteworthy examples of the art that might haxe otherwise been deployed. Typical of such art are the hundreds of stained glass designs "tiered tor sale bv I niterl Housew reck ing Company of Stamford. Conn. The wmipanv. which specializes in selling -tained glass windows, doors, etc., that ue n-miiwd from wrecked churches and houses, has played a major role in the renewed interest in and the availability I -tained glass in New [xngland. typical of the regional chain stores 'hat ha\ e recently opened to supply the demand for stained glass decoratixe `terns are the fixe operated by The Horseman Antiques. Inc. Most of the stained glass sold bv the five stores, "hich are located in New York hity. comes from demolished buildings, dually reframed in wood, the stained , -'lass is either hung just inside windows mi that sunlight illuminates tlie design or else it is back-lighted on a wall. Decor Studio. located in Manhattan, is tvpicai >f the xclusive boutique-txpe of -hop that specializes in custom-de signed stained glass. The company, which advertises itself as "the people who brought back stained glass studio and custom-designed window, xxall and lighting creations" features such items as a 22 in. diameter stained glass Tif fany-style light shade that sells for $540 to large wall hangings made of stained glass costing thousands of dollars. \s part of the renewed interest in leaded stained glass, courses in the art are being taught in colleges and unixersities. Many major department and specialtv stores now have -tained glass de partments and stained glass "do-it-vourself -hops are opening up all across the country. Mail order companies such as (Mass Masters Guild, located in New fork City, have developed special kits that contain instructions on how to be gin designing with leaded stained glass. Religious themes, street number sections, and period pieces are most popular with collectors. I1 NONDESTRUCTIVE TESTING is M i i Cinderella's fairy godmother had her famous wand that provided all Some of the major industries that depend on XDT for quality control are kinds of magical gifts and industry the automotive, casting, forging, ship has a similar magical device that can be building, iron and steel, welding and used to make sure products and ma brazing, aviation and aerospace and terials can meet required levels of ser other specialized industries. vice and performance. The magical de vice is called nondestructive testing. Of the various techniques used in XDT, radiography is one of the most Using nondestructive testing, or XDT, versatile and widely used. Employing industry can achieve dependable, eco highly penetrating X-rays, gamma rays nomical quality control for products and other forms of radiation that do not and materials without having to cut, damage the part itself, radiography pro core, peel, scrape or otherwise damage vides both a detailed, clearly visible or destroy them. The technique provides X-ray view as well as a permanent rec access to an area or section that requires ord of internal conditions. visual inspection to determine if a pro duct or material will perform as de Despite its advantages, there is an signed. XDT can "see" inside welded inherent danger in the use of XDT joints to determine if they are properly radiography. Particular care must be joined, and it can permit quality con taken to insure that operators of the trol examination of the entire interior equipment, and personnel working ad and exterior of products without having jacent to it, are shielded from radiation to damage them or otherwise impair since the failure to do so can endanger their usefulness. the human body. One of the primary materials used t0 design X-ray radiation shielding is lea(j Although lead's primary quality is siveness, its use in shielding almost in variably saves weight and space. And since density is of paramount impor. i tance, lead is often selected because it jj | the densest of any commonlv available | material. The metal's low cost, and the ease with which it can be cast, extruded, ! rolled, machined and otherwise formed, ! combine to make it one of the moat i efficient shielding materials. j Three typical examples of lead's use 1 as a protective shield in XDT radio. I graphic applications involves its use in research and development and for quality control in the tire manufactur ing and foundry industries. Sandia Laboratories, Albuquerque, New Mexico, is an example of how XDT is used for research and development The company is a prime contractor to Tire for huge earth-moving machine Is X-rayed In lead-lined room. INDUSTRIAL q u a l it y c o n t r o l the \tomic Energy Commission, and is imaged in research and development of n,,n.nuclear weapon development. tandia's Nondestructive Testing Lab oratory houses a mobile 10-million volt \.rav machine, which can operate at 5 jrl(j 5.7-million electron volts. Mounted on the front end of a specially-modified fork lift that can tilt, rotate and swing, t(,e X-ray machine's flexibility is such that it can check the internal structure of materials in assemblies. X-rays are pro jected from the machine to film mounted behind the item undergoing study. To ensure protection from radiation, all instruments in Sandia's NDT facility are controlled remotely from a con sole in another building and the lab oratory is evacuated during exposure. However, as an additional precaution, lead is used for some shielding and the cell walls were constructed to permit the addition of %-in. of lead around the "rer perimeter. A typical tire manufacturer utilizes NDT to selectively test as many as 18,000 tires per day by sending them through an X-ray inspection unit that is capable of carefully screening more than 200 tires an hour. One such unit is man ufactured by the Picker Corporation, Cleveland, Ohio, and it is used by a company that produces tires for various commercial and industrial vehicles. A conveyor belt carries the tires through the unit during which time they are positioned, inflated and rotated under the X-ray machine. Situated out side the unit is a master control panel which reveals an X-ray view of any tire defects. Enclosure panels surrounding the machine on the sides and top con tain Vg-in. of lead sandwiched between 0.004 and 0.006-in. of steel. Visual in spection of the unit can be made through a leaded glass viewing window situated near the master control panel. The company also produces NDT equipment used by the electronics, ord nance and other industries to insure that products are manufactured to comply with required military or industrial spec ifications. Oberdorfer Foundries operates a full range of casting services in aluminum and copper alloys. The company serves aeronautical, automotive and other in dustries with castings ranging in size from a few ounces to some weighing more than 1000 lb. At Oberdorfer's sand casting foundry in Syracuse, N.Y., casting quality is checked by NDT radiographic hardware in an 8 ft. by 10 ft. X-ray chamber lined with i/g-in. sheet lead. Castings are placed on a lead-shielded table above which is suspended the tube head of a 250 thousand volt X-ray unit, the larger of Oberdorfer's X-ray machines. For castings requiring less radiation penetra tion, a portable 100 thousand volt unit is employed. HEARING-LOSS: BIG INDUSTRIAL HEADACHE Noise pollution is one of the most serious problems facing industry depending on how carefully the en closure is installed and the origiral today. Statistics show that more than noise levels encountered. 10 per cent of the country's working population suffers some noise-related hearing impairment. It has even been suggested that workers subjected to the highest industrial noise levels are prone to heart disorders, circulatory and equi librium problems. The furniture plant machinery noise enclosure is designed to bring 98 dBA so nd lewis outside the unit to 90 dBA. This is the sound level at which OSHA regulations say a worker can perform tasks for eight hours. It compares to a sound level of 115 dBA at which a work As the result of such problems, the er can perform for only 15 minutes un Occupational Safety and Health Act less protected from the noise level which lOSHA) now requires that any industry is so high that conversation is impos with noise levels of more than 90 dBA sible. The enclosure design features must provide a hearing conservation openings at either end so that wood of such equipment used a steel shroud program for its employees. This require furniture components can enter and laminated to a combination lead, foan, ment encompasses approximately 40 leave the work station, a combination sound barrier to achieve a 67 per ce per cent of all industrial manufacturers, saw and milling operation. Glass panels decrease in noise for its line of /oqq and it is expected that approximately installed in the sides of the enclosure CFM packaged centrifugal compressor SI.8 billion will be spent to implement permit an unobstructed view of the The reduction, initially achieved in , the hearing conservation program in work being performed and, in addition, test of the steel shroud and lead, f0aa compliance with OSHA regulations. allows visual communication between combination, marked the first time such Most of the funds allocated by indus try for noise control will be spent for new products and systems that will dampen, muffle or insulate machinery noises. Because lead offers excellent sound insulation properties and can be tailored to meet the various specific de mands for noise control, it is being in the operators, who wear ear plugs or mufflers, and their supervisor. Compressor Noice Control In the second application, the use of lead to decrease centrifugal compressor noise, one of the largest manufacturers equipment operated with a sound levd of 84 dBA. This noise level compara to the sounds heard on a busy street corner. Until the steel shroud and lead/ foam combination was developed, noise control of centrifugal compressors was considered more serious than noise from reciprocating or vane-type compressors. corporated into many of today's new hearing conservation products. Some typical examples are its use in a spe Gear and Impeller section of compressor (L) prior to instaiiation of noise barrier, and (R) with steel shroud covering lead/foam acoustical system. cially designed, sound-insulated en closure for furniture machinery; to re duce the sound of a large centrifugal compressor by 67 per cent; and to de crease the sound of a plastics grinder/ granulator by 85 per cent. Lead/Foam Machinery Enclosure Panels The furniture machinery enclosure, installed in a plant that produces wooden furniture, is a panel system consisting of two (A psf. (.0078 -in. thick) sheet lead septa sandwiched in acoustical foam. This combination is, in turn, bonded to the backside of the metal exterior and interior face panels. The system meets regulations for fire retardance and it is designed to meet OSHA standards Modular jane! system incorporates lead/foam comoination to reduce furniture machinery noise ieveis. | The 84 dBA reading represents a 67 ] per cent decrease in noise levels. By t comparison, the original levels were as ) high as 100 dBA, a noise level that com pares to a blaring radio. An employee a may work in the vicinity of 100 dBA i noise levels for only two hours. j Noise reduction in the compressor was achieved by covering those areas " of the unit where most of the high-level noise emanated. The areas, located in the mid-section of the unit, included the main drive gears, impeller vanes, and the gear-type oil pump. The multi-layer shroud and lead/foam combination was used to enclose the mid-section. The lead/foam combination consisted of a 1 psf (.0156-in. thick) sheet lead {sound barrier sandwiched in an inchthick layer of foam. It was applied over a previously sprayed-on undercoat layer and then a steel shroud was placed over I ! i the top of the enclosed section. To con duct away heat build-up within the shroud, specially designed louvers were placed at the bottom and top of the enclosure. Scrap Grinder Silencer The third application involved lead laminated directly to steel. This applica tion solved a major noise problem found in the plastics industry where the noise of machinery grinding or granulating today's tough, hard plastic materials must be controlled. Some of these oper ations produce noise levels that are as high as 88 dBA two feet from the grinder, a level that is in excess of OSHA allowances. To solve such problems, one plastics processing plant with five grinding ma chines launched a special project to redesign its grinding equipment. Since the company had five machines, down time required to silence the equipment had to be kept to a minimum. In the first installation, sheet lead was laminated to the interior face of all hopper walls, underneath portions, and the interior of pedestals, stands and covers. This required 20 hours. In the next installation, the outside face of two machines was laminated in 15 hours and because this technique was faster and just as effective, it was used to at tenuate the sound of the remaining two machines. This technique had the addi tional advantage of permitting spray painting to match the color of the ma chine. Each machine required about 25 sq. ft. of 2 psf. i.0312-in. thick) sheet lead. A special urethane adhesive was utilized, and the installation work was accomplished by a mechanic. Total cost of the job for labor and ma terials was 3100 per grinder. The sound meter reading after the lead was lami nated was 64 dBA. a drop of 24 decibels, and a sound level at which normal voice communication is possible at 3 - ft. dis tance. The company reports it achieved a noise reduction of approximatelv 85 per cent. Lead laminated directly to exterior face of plastic scrap grinders reduced noise Oy 85%. FOR CHANGE OF ADDRESS PLEASE WRITE IN NUMBER FROM TOP OF ADDRESS OR ATTACH OLD LABEL. Q ADD ME TO YOUR MAILING LIST (pleas* check one) V ATTACH MAILING LABEL HERE ________A_________ To ____________ Name, Title Company PLEASE CHECK INTEREST Painting Health & Safety Q Architectural & Building Design & Radiation Engineers Ceramics Chemical Engrs. Battery Power T Miscellaneous (please specify) Street City, state, zip code nr LIA 26691 NEW LISTINGS Lead In Building A four-part data sheet containing informa tion on waterproofing, sound darners, roofing and flashing and anti-vibration ap plications A-13 Lead Keeps Classrooms Quiet Reprint illustrates how sheet lead was in stalled as plenum barriers between rooms iri a Greenlawn. N.Y. school. Lead-shielded audiometnc room will provide accurate hearing tests. J-13 Practical Application Of Sheet Lead For Noise Barriers Discusses how the use of various thick nesses of lead bonded to or used m con junction with other construction mate rials determines the Sound Transmission Class ,STC) rating of walls and partitions. J. 15 A Crackling Market for Electric Forklifts Business Week reprint details the upsurge m use of electric forklift trucks m com pliance with stricter Federal and other antipollution regulations , L-lfi Publications and Films Twelve-page catalogue listing the publica tions and films available from The Lead industries Association. Inc. M-13 Facts About Lead And Pediatrics Presents data on prevention and control of lead absorption by both adults and children. Particular emphasis is placed on preventing lead intoxication in children from such sources as old leaded paint usually found m poor housing within pov erty areas. M-20 Childhood Lead Poisoning Highlights on Midwest and Eastern con ferences where childhood lead poisoning were discussed. Prepared in cooperation with the American Academy of Pediatrics. M-27 Soldering Preforms Circuits Manufacturing reprint discusses how the use of lead solder preforms save time and simplify task of joining metals for automated production. M*28 ARCHITECTURAL Lead roofing and flashing Detailed instructions on the simplest and most usual methods for forming or join ing lead for roofing and flashing appli cations. Complete specifications. Dia grammatic drawings. Sixteen pages. A-5 PAINTS Follow the safety line with chrome yellow Formulations and suggested applications for chrome yellow safety paints. Illus trated. Eight pages. F-5 CHEMICAL CONSTRUCTION & CORROSION PROTECTION Corrosion resistance of lead in chemical applications A chart presentation of the corrosion re sistance of lead and its alloys against 188 chemicals from 0 to 3000F. Six pages. H-3 BATTERIES A primer on the lead-acid battery A condensed story of the principles of the lead-acid battery and its chemistry, in cluding some of the fundamentals and definitions of direct-current electric en ergy. Two pages. L-6 Lift profits electrically Provides performance data on electric battery powered vehicles for industrial use. Cost calculators are designed to help buyer estimate depreciation, operating and maintenance costs. Sixteen pages. L-14 CERAMICS Facts about lead glazes for art potters and hobbyists Detailed information on the proper formu lation, firing techniques, handling, etc. of lead fluxed glazes used by art potters and hobby ceramists. Illustrated. Sixteen pages. 8-11 SOUND BARRIERS Directory of acoustic specialties Summary of available materials for sound insulation by barrier, damping and absorption methods. Sixteen page list of materials by brand name and manufac turer. Eighteen pages. J-4 Lead a major factor in new machinery noise suppression systems Description of techniques used to lower machinery noise levels with lead and lead composites. Lists machines that normally exceed noise level allowed by WalshHealey Public Contracts Act. Two pages. J-9 Controlling sound with lead Reprint cites three installations where lead is being used as a noise and vibra tion barrier: John Hancock Building: Baldwin-Wallace College; and New Eng land Medical Center. Boston. Four pages. J-12 Sheet lead plenum barriers Detailed description of acoustical plenum barriers and how to install them. Mate rials and installation procedures described and illustrated. Eight pages. J-10 ANTI-VIBRATION PADS Ways to reduce press vibration Two installations of lead asbestos pads to reduce heavy machinery vibrations. Sec tional drawings and loadings are given. Two pages, illustrated. G-l Lead asbestos anti-vibration pads Specifics on lead anti-vibration pads in cluding design and sizing, specifications for the sub-contractor, and list of pad manufacturers. Three pages. G-3 CABLE SHEATHING Lead-covered underground cable use increasing Reprint outlining a major utility's recent experience with lead sheathed under ground cable. Details on where this type cable is desirable. Graphs. Four pages. C-2 GENERAL Lead Welding Reprint from American Welding Society Handbook, covers methods of welding lead, joint design, torch manipulation and welding speeds. Other sections cover safety promotions and common applica tions. Bibliography. Fourteen pages. 1-1 The U.S. Lead Industry--1972 An annual review of activity with; dustry that contains a general I?*** for the year and a senes of ch tables giving current statistics ,, production and consumption. M-lt R Primary lead production areas in the U.S. For schools, libraries. U"xl4' a,a_ mg locations in U.S. of most lead and refineries, and lead mines. M-ii*** Lead--A Modern design material Summary of properties and av , forms of lead for radiation -oil*1 sound/vibration control, electrical".-.*1 sources, soldering and ceramic* pages M-15 ' The new lead belt Reprint of article details operations new lead belt in Missouri. Booklet scribes activities at four mines, fourcentrators and three smelters, f pages. M-16. Use of lead in the automobile Reprint of article from Metals cussing in detail the various appi tions of lead in the automobile, p pages. M-17 Lead--The "Clydesdale" workhorse in space Reprint from Space World detailing applications of lead in space expioratjIllustrated. Four pages. M-19. Ecology in the new lead belt Reprint describes cooperation of indand environmentalists in develop southern Missouri lead mines. Fpages. M-23 FILMS Lead Matrix A 26-min., 16mm color film. De strates that lead is one of the basic ments in the matrix that binds our cr zation together. To order, specify desi show date and one alternate date, charge to borrow; viewer pays only turn postage. N1 This magazine is reproduced from lead type PRINTED IN U.S.A.