Document 4JvZZwvZpreVvOE0kN8KkaEGp

'ntcrir* Ultrasonics at work A Vest-pocket Oil Burnei Conventional (left) and ultrasonic oil burner. (Courtesy Esso Research and En gineering Company.) Today, an ultrasonic horn is making "sweet music" in the ears of engineers at the Esso Research and Engineering Co., Linden, N. J.1 While the engi neers cannot actually hear this "mu sic," they like the tune, because it makes possible a remarkably compact little oil burner which may invade the domestic hot water heater market and other sizable markets. Key to this new development is an ultrasonic atomizing horn activated by PZT, a lead zirconate-titanate ce ramic which is currently finding ex tensive use in sonar and ultrasonic cleaners. When high-frequency volt age is applied across a crystal of PZT it expands and contracts in harmonv with the pulsing current. These vibra tions produce ultrasound (sound fre quencies above the range of human hearing). Of the many transducer ma terials known which exhibit this abil ity to convert electrical energy into sound waves, lead zirconate-titanate is one of the most efficient. Faced with the results of a study showing that sizable new markets for fuel oil awaited such a development. Esso Research engineers set out to create a compact, low-firing-rate oil burner. Shooting for a rate of 0.2 gph (gallons per hour) -- conventional burners are not reliable at rates below 0.6 gph -- Esso researchers concluded that ultrasonic energy, produced by PZT, offered a practical solution to their problem. Ultrasonic waves atomize the fuel and at the same time allow for a much lower rate of feed. This is because the high-energy sound waves literally blast clean the feed tube -- making the burner self-cleaning. Conventional burners tend to plug at these very low feed rates, as they do not have the advantage of this built-in purge. To achieve sufficient sound ampli tude to atomize the fuel it was found necessary to magnify vibrations of the PZT by means of a horn, in much the same manner as a cheerleader inten sifies his voice with a megaphone. Much experimentation and a good knowledge of acoustics were required before the engineers settled on a satis factory design. Initially, horns were built with an epoxy resin cement used to bond the leaded ceramic disc to the metal walls. Heart of the ultrasonic oil burner is the atomizing horn. Shown here in a cut away view, the horn contains a lead zirconatetitanate ceramic transducer which ultrasonically atomizes oil in the feed tube for better burning. However, this was inadequate due to bond deterioration and the time-con suming care necessary to get good bond. On the other hand, mechanical clamping of the disc to the horn also presented serious problems, not th least of which was damping, j.e., th clamp restricted vibration of th transducer. The damping problem was ingenl ously solved by the addition of dummy horn (see drawing). Eac horn is designed to produce a i plane at its shoulder, thus the damtj ing effect of the clamps is negligible The horns are made of aluminun which has a high vibrational qi (Q) factor, and the unit is designe for service in the frequency range 60,000 cycles per second. An ele tronic driver tube, or oscillatoif powers the transducer, and power out] puts of up to 6 watts are common will) single tube equipment. A variety of life and field tests havi been conducted with the new burner] One was in a center-flued hot wateg heater with #2 heating oil. It operate^ very well throughout the range from 0.2 to 0.7 gph. The burner 1 also been run continuously for 500 hours, whereupon the tests were voB untarily concluded. Esso Research estimates that it] ultrasonic burner can be manufac tured at about the same cost as a con ventional oil burner unit, and it offer many advantages over the latter: con pactness, no high-pressure oil sup requirements, self-cleaning passage and good performance at low 1 rates. At the present time Esso is offerinl interested manufacturers a license tj| make and sell ultrasonic burners the U.S. and Canada. 1. "An Ultrasonic Oil Burner" by J. C. Young, J. A. Wilson and R. J. Lang. A report of tbe Fs*n r.,,,;r,.>,,rjng (y0 Linden. N. J. (1962). LIA262 85 f|,ey jo the twist! Rig containing aluminum mandrel and self-propelled crane straddles a row of concrete cells while lead burners inside the rig horizontally weld two sheets of lead to form the cell lining. Cell on left has received finished wall lining. 600 TANK LININGS-- NO VERTICAL SEAMS Sitting inside the cell, workman welds walls to floor. Only three sheets are re quired to fabricate the lining. Exploded view (inset) shows position of the three original sheets. Construction time on the largest lead construction project ever under taken in Canada has been halved by the development of a method that avoids burning vertical welds. Installing sheet lead linings in 600 large zinc reduction cells at Canadian Electrolytic Company's new reduction plant at Valleyfield, Quebec would normally require a long, tedious and difficult weld up each vertical edge. The new method cuts the time and number of men required for the proj ect in half. Key to the new process is a hollow aluminum mandrel corresponding to the shape and size of the interior of a cell. The mandrel is carried by a selfpropelled crane that straddles a row of cells and moves the work from cell to cell. The entire rig is enclosed so work can continue through the winter. In fabricating the liner, two sheets of chemical lead are fitted around the mandrel to form the four walls of the cell so that only two weld seams are required where the sheets join at diag onally opposite corners. The sheets are welded together by a team of opera tors inside the mandrel which is lying on its side so that the seams are horizontal. When the first two sheets are welded together to form all four cell walls, the mandrel is removed, the liner is upended and lowered into the cell. Another team of lead burners then welds a third sheet of lead at the cell bottom, while the first team moves on *nd repeats the process at the next cell. When the plant is completed the 600 cells, lined with more than 500 tons of lead will be used for the electrolyz ing of a zinc bearing solution to ob tain zinc cathodes. Lead linings are used because of the metal's resistance to corrosion by the strong acid used in the process. As an additional pre caution against corrosion, each con crete shell is sized with sodium silicate before the lead lining is installed. More sheet lead covers the concrete columns supporting the cells to pro tect them against acid spillage. The new plant, jointly owned by five mining companies, will cost $20 million. WTien it goes into production in the fall of 1963 it is expected to produce 200 tons of zinc per day. The new method was developed by Armand Piche of Federated Metals Can ada Ltd., a subsidiary of American Smelting and Refining Co. These 12 foot high concrete columns will support the completed cells. The columns will be lead sheathed to protect them from acid spillage. \ LIA262 86 THE MAGIC OF STAINED GLASS Definition of "window": "An opening in the wall of a building for admission of light and air, usually closed by .. . glass . . ." --Webster's New Collegiate Dictionary, 1961 by G. & C. Merriam Company Another definition (by a seven-year-old boy on his first visit to Notre Dame Cathedral in Paris): The lad entered the cathedral just as the organ started to play. His eye caught the rose window and he exclaimed, "It sings, the window is singing.'" The boy was Viollet le Due and his revelation of the effects of stained glass did much to revive the art in the last century. Great stained glass windows do more than admit light. They actually vibrate to it. Any good window functions architecturally to keep out rough weather. Great stained glass window's function spiritually as well. Todav craftsmen and designers combine pure art and modern science to produce superb creations that mark a mastery of light and pure color, controlled by lead lines and painted patterns which lose nothing in comparison with their illustrious medieval proto types. In this country today craftsmen work in much the same fashion as their predecessors did seven or eight hundred years ago. Probably the reason is that the real beauty and aesthetic-architectural appeal of stained glass can be accomplished in no other wav. One of the foremost practitioners of this philoso phy is the Jacoby Studios in St. Louis. Missouri. A fine example of their art illustrates this article: -- the first Presbyterian Church of Kirkw ood. Missouri. Fischer & Campbell Assoc, of Clayton, Missouri were the architects with whom the designers worked al most from the first sketches for the church. In fact, this was a collaborative effort in the truest and finest sense of the word. The church committee, early in the development of the designs, was brought in for counsel and advice. The minister provided guidance in choice of biblical texts to be portrayed. The chief designer, whose w'ork in this instance was a culmination of a lifetime spent in designing sta glass windows, had the able and often inspire sistance of a happy mixture of apprentices and timers." The thirteen windows in the apse, as shown i illustration, are each 4-0" wide by 27'-0" high vided into nine sections supported by lead coat irons anchored into the masonry openings. Siz lead cames vary from ;V to 1" flanges and over two tons of them were used. Mam parts of the window were "plated," th two pieces were laminated or combined to acl a color not obtainable with a single piece. No the glass was coated with paint and the desi actually personally selected each piece of glass in a total glass area of 1.400 square feet. Other the w indows in the apse, there are about 100 s windows including 75 geometric "symbol'' win on the East wall and 10 on the West. "These are exciting times." says Mr. Willia Oppliger of Jacoby Studios and though they keeping abreast of them and are doing some in the newer epoxy resins, etc., "nothing will replace the beauty and effects achieved throug use of stained glass. Over the centuries, lead have proven to be the ideal material with whi bind the designs of all sizes and shapes in col stained glass." LIA26287 4-- -- A reol view from this picture window over looking San Froneiseo Bay. The lead-cov ered plant boxes form a neat, tasteful border to the picture. Lead andJntorier Decoration mm Take an urban balconv or terrace, add plants in plant boxes, provide the proper furnishings, and you have a pleasant spot for a twilight chat or a breather through the day. But too often you also have an insufferable problem of protecting those furnish ings from the weather -- or. as an alternative, an unintended rustic air as sunlight, rain, and airborne dust destrov them. A solution to this "exterior decorat ing" problem in one San Francisco apartment has been the use of 21 L>pound (just over 1 32") sheet lead. Plant boxes and cabinets were made up in inexpensive redwood 1x6 planks and finished with the easih worked sheet. By lapping it over top and bottom edges by about 21 6 inches, the major fastenings for the sheet all fall in hidden areas. Then, to break up the flat expanses, V* inch diameter half round extruded lead rod was fastened to the sheet to form rectangular panels. The result is elegant and unobtru sive. The terrace is urban, comfort able and above all practical. In the year and a half since the lead was first put out it has required no main tenance of any kind. The surfaces have developed the soft gray patina which pleases the eye without diverting at tention from the plants or the un rivalled beauty of the Bay Area skyline. LIA2628f --5-- \v.ur. m The storage cabinet is waterproof, weatherproof, and worryproof thanks to a sheothing of 2j/2-pound sheet lead. Redwood and lead sheet form the plant boxes, too. "f iff PATROLLING the parking lot of o large shopping center on a two-passenger Cushman Truckster has virtually eliminated van dalism and cor break-ins. The silent battery powered motor enables the patrolman to be on top of a trouble spot before he can be heard. The small, three wheeled vehicle can dart into traffic tieups and other tight spots. Use of ten similar one-passenger vehicles by the guard force at Westinghouse Electric Corp.'s huge East Pitts burgh, Pa. plant (cover picture) provides greater protection against pilferage, storage and fire hazards. Small vehicles powered by rechargeable lead acid storage batteries are excelling in a wide variety of jobs in school, industrial and commercial plants, airports and resorts around the country. Here are five representative examples of the versatility of the quiet, speedy and economical vehicles. TRAFFIC CONTROL and operational maintenance on Philadelphia's Tacony-Palmyra bridge is mode more efficient and safer for operating personnel by use of two battery powered Cush man Trucksters. The small vehicles, manufactured by Cushman Mo tors, subsidiary of Outboard Ma rine Corp., Lincoln, Nebraska carry maintenance personnel, such os this paint crew, along the spon's narrow walkways. The vehicles olso stay out of traffic lanes while speeding such operations as bridge openings for ships, lone switching and coping with traffic accidents. RUSHING HOT MEALS to handi capped children in a cottage-type school is the |ob of this food train pulled by a battery powered vehicle. The train not only gets the food to the decentralized homes of the fa mous Arkansas Children's Colony quickly but it does so silently. ook Ahead with Lead a WAREHOUSE TRAFFIC control I in o wholesale grocer's large wareuous* Hs been speeded since the worehouse supervisor took to a small Cushman Truckster. His job, directing the movement of 2/i million tons of dry groceries and frozen food within the ware house each week, demands rapid travel between many locations. The battery powered vehicle is fast, small enough to move down the aisles without tying up other traffic, and ideally suited to indoor use becouse it emits no fumes or odors. GUESTS and their luggage ore carried comfortably to their rooms at a popular Scottsdale, Ariz. hotel in this fringe-topped, battery-powered "surrey." Other battery powered vehicles are used to deliver food, ice, mix, and messages to guests. The hotel soys it overages 50 miles on a charge. 6-- - LIA26289 Torture test. Leod-cured Hypolon (block) and conventional wires hove been subjected to o temperature of hundreds of degrees in the tip of this soldering gun. This overload would never occur in normal service, but duplicates a typical shortcircuit condition. When wire has to be Tough |B lead-stabilized plastic is the answer The president of a large electric utility once said, "Nobody even real izes we exist until the meter reader steps in the tulip bed or the lights go out." Electric power is certainly one of the things we take for granted. Without ever knowing how much or what kind of wiring we have in our homes, appliances, cars, and offices, we expect the lights to go on when we flip the switch. And we are hardly ever disappointed. But consider the really rough oper ating conditions wire encounters, say, in a mine, and you can see that reliable operation is a minor miracle in its own right. Rapid changes of work site re quires mine cable to be dragged over sharp edges of freshly broken rock. The wire may sit for days or months in water. Moisture and constant tem perature are just the right conditions for fungus attack to the insulation. And heavy equipment and roughshod miners don't treat the wire like a lace napkin at a Sunday tea. In really demanding situations like this, litharge stabilized Hypalon syn Performance of Hypalon Mine Cable (Bronco M16IM Poraliel Mining Mochinc Cable by Western Insulated Win Co., 2425 E. 30th St., Los Angeles 58, Colif.j Size and construction. integral insulation & jacket of litharge-cured Hypolon, #6/2 cable 0.51 x 0.84 inch Allowable temperature.. 90C cont. Current capacity........... 76 amp Insulation tensile strength.... 1750 psi elongotion .......... 240 per cent resistance ............ 53 megohm/1000 ft power factor........ 3.2 per cent thetic rubber is winning plaudits for month after month reliability. Hypa lon is well known for its resistance to aging and breakdown through oxida tion. Lead -- in the form of litharge used for curing and stabilizing the synthetic--contributes to its top rated moisture resistance and electrical per formance. About 13.3 per cent litharge is used in the manufacture of the Hypalon insulation of Western In sulated W'ire Company's mine cable. In addition to its vulcanizing-stabilizing role in this formulation, the lith arge contributes reinforcement. Besides these prime characteristics, litharge-cured material has a good many secondary benefits to offer. Its electrical and physical properties are so good that a cable of paired #6 wires is no larger than conventionally insulated #8 wire pair cable. Since Hypalon is light in color and retains tints extremely well, bright yellow is used for maximum safetv. The insula tion is easy to strip. It is flame re sistant and stands temperature so well that operation at temperatures up to 90CC is recommended -- allowing a 17 per cent bonus flow current (76 instead of 65 amp for #6 wire). f The Roof's This Russian Orthodox Church, recently completed in Campbell, Ohio has attracted attention as far away as Moscow in the USSR. Architect C. R. Johnson has achieved all the desirable features of contemporary architecture without deserting tradition. The typical onion-shaped dome and the parabolic roof of the main structure blend interestingly. Teme roofing-lead-tin alloy coated steel - made possible the dean design. LI A 262 9C 7 The Thing! t ACTION AND COLOR CAPTURED ON METAL! These bowls, panels and vases were designed and executed by Cleveland artists Ed and Thelma Winter. Pic tured are only a few of the 82 pieces they have on display now' through January 28, 1963, at the Suffolk Museum, Stony Brook, Long Island. Leaded "jewelers" enamels are used by the Winters to depict lively horses, birds, flowers and other subjects with skill, warmth and charm. The Winters create their own designs which are then fused permanently to metal substrates in the enameling furnace. Fea. tured in more than 125 museums and galleries throughout the world, Mr. Winter's enamels have been fired on such diverse metals as copper, silver, steel, aluminum and stainless steel. Mr. Winter has recently published the second in a series of books on enamel, ing. "Enamelling for the Beginner," I Watson-Guptill. N.^.i. in which he points out the many advantages found in using lead-bearing enamels. ujLjIjBjRARijYj\OxFuTjEjCyHNuICAjLjiqINuFOif The following publications are available free of charge unless otherwise noted. Send request to the LEAD INDUSTRIES ASSOCIATION, 292 MADISON AVENUE, NEW YORK 17, N. Y. NEW LISTINGS Silver Anniversary Roofs Case histories of four sheet lead roofs each with 25 or more years of service. GENERAL Lead in modern industry (request on company letterhead, please) 230 poges, hardboard. Describes all phases of the production and uses of lead, its alloys and compounds. Discovering the Beauty of Lead New uses for lead Design engineering data BATTERIES Electric delivery trucks Truck costs in a jiffy The choice of battery systems CONSTRUCTION Building construction bulletins 1. Specifications - lead waste connections, plumbing 2. Specifications - lead shower and safe pans 3. Specifications--chemical laboratory drain age systems Lead work for modern plumbing $2.00 postpaid. S1.S0 per copy in orders of 10 or more. Materials of construction reviews lead and its alloys in design and construc tion for research and engineering use. Seamless terne for roofing Lead to control sound and vibration Sheet lead Tor roofing and flashing Lead plumbing ENGINEERING New Ceramic Data Transducers for ultrasonics Thermoelectric materials today Corrosion data -- lead & alloys Methods of lead lining tanks lead-asbestos anti-vibration pads Cutting press vibrations Oilless bearings -- helicopters 1000F bearings Nuclear materials Amazing new spark pump All about lead welding FINISHES Decorative finishes for lead Red lead based paint systems UPON REQUEST, THE LEAD INDUSTRIES ASSOCIATION WILL BE GLAD TO MAIL "LEAD'' REGULARLY, FREE OF CHARGE, TO THOSE INTERESTED, AND WILL COOPERATE WITHOUT OBLIGATION IN THE SOLUTION OF YOUR LEAD PROBLEMS. LI A26291 aduced by letterpress from lead type. PRINTED IN U.S.A. PUBLISHER? PRINTING -- ROGER? KEI.LOGC CORP LONG ISLAND CITY j. N Y