Document VGQ5BgGLOMmY7er7orOXyVb9g

NEW MARKETS . . . NEW OPPORTUNITIES FOR LEAD On the surface, it may seem strange that the lead industry, which for the last several years has been enjoying a reassuring period of increased con sumption, should be seeking additional markets. Vet, that's exactly what's hap pening. And the search is likely to result in new opportunities for marketing of lead. -- The reason for the current stepped- up market development activities stems from lead's heavy dependence on a sin gle market--the automotive industry. In this prime sales area, lead is being phased out of gasoline in the United States. As a result, the lead industry must seek new markets for the lead formerly used in antiknock additives. There is also the need to create new markets for the lead used in automobile storage batteries as new competitive storage battery systems emerge. In the U.S., antiknock additives required 194.000 short tons and storage batteries 960,000 short tons out of a grand total of 1,547.000 short tons of lead con sumed in 1978. The logical way for the lead industry to overcome its present market de pendence on gasoline-powered automo biles is to develop new uses and markets for batteries. A most promising new application for batteries is to power what many people believe to be the next generation of vehicles--electric cars. opportunities exist for large numbers of The lead industry and the federal gov batteries for load-leveling purposes. ernment have committed millions of Another exciting area which should dollars for research and development of provide a potential growth market for improved lead batteries to power electric vehicles and hybrid vehicles, the latter powered by batteries and another power lead batteries is the solar electric energy industry. As this industry grows there could be a large-scale need for lead source. Many thousands of these vehi cles are expected to be in use on the batteries to store solar generated elec tric power in remote locations and even nation s streets and highways in the next five years. tually for use in homes arid commercial establishments. The lead industry also is taking a Last, but not least, lead with its hard look at other battery markets that superb sound-barrier characteristics, might be expanded. One such market is should find w ider use in reducing noise in the electric utility industry where pollution. hile the problem of the heavy de pendence on the automotive market should not be underestimated, recent activities by the lead industry show that it is determined to solve its problems by finding new and expanded outlets for this important, strategic metal. W, 7. Meyer President Lead Jndust/ies Association, Acoustical curtains come down on noise Gates Learjet Corporation has in stalled lead impregnated curtains at areas. Although personal protective equipment (P.P.E.) was being used by its Wichita, Kansas plant to muffle the these employees. Federal Safety Regu noise from riveting operations. The lations require engineering controls be company was concerned about the effect exhausted before P.P.E. can be utilized of high noise levels from splice plate for compliance purposes. riveting on jet aircraft assembly person Because noise containment and vibra nel at the plant. tion dampening are essentially the only The area of concern centered on the engineering controls available for pneu manufacturing location where aircraft matic riveting operations, the company wing sections are assembled. The pro chose to install Quil/Teez acoustically- duction sequence in which splice plates insulated panels around the wing shop join wing sections through pneumatic area. These panels, manufactured by riveting operations creates noise levels Noise Control Associates, Inc., Mont ranging from 118 to 122 dBA. clair, N.J., combined lead and fiberglass Noise levels generated within the enveloped in an aluminized glass cloth to machine shop and wing final assembly act simultaneously as a noise barrier areas were less than 80 dBA (time and a noise absorber--the fiberglass weighted average). However, the higher absorbs noise energy while the lead noise levels produced by the splice plate septum acts as a transmission barrier. operations overlapped into these areas. A pair of 20-foot x 30-foot Quil/Teez Frank Gagne, Jr., supervisor, Safety curtains were hung on reinforced grom & Industrial Hygiene, at Gates Learjet, mets and bolted to an overhead track. said high noise levels created morale One particular section of the wing was and fatigue conditions which reduced selected for the evaluation of the cur effectiveness of workers in the adjacent tain's effectiveness to insure that con stant sound pressure levels were being surveyed. Readings were taken using a sound level meter and graphic level recorder. The meter was positioned in the machine shop (12 feet from the noise source) and readings were taken--first with the curtains open and then with the curtains closed. The reductions achieved through the use of the noise attenuating/absorb ing curtains was 10-12 dBA. According to Frank Gagne, the instal lation of the acoustical curtains `"has im proved employee morale, eliminated the need for hearing protection in adjacent areas, and. hopefully, will increase pro duction, reduce fatigue and errors in the machine shop and wing final as sembly areas." He points out: "Lead is an excellent choice for noise attenuation for problems similar to ours." He also adds that bags filled with lead shot nr jsand and used as vibration dampeningiw**-. devices can help to obtain as much as a 7 dBA reduction in sound pressure levels in certain operations. i Wing Shop Area. With leaded acoustical curtains closed, workers in the adjacent areas ot the wing final assembly and the machine shop are protected Uom extremely high noise levels Irom pneumatic riveters used in this location. Acoustical lead barriar curtains protect workers in the machine shop (left) from high noise levels. Splice plates being riveted. Acoustical curtain in background prevents high noise levels from overlap ping into the machine shop and wing final assembly areas. 3 Battery-powered industrial trucks prove out under extreme material handling conditions A random tour of industrial plants throughout the United States would have been cut, electric fork tifts take over the material handling reveal an increasing dependence on leadthroughout the plant. P eratiotu battery-powered trucks to handle large daily volumes of material and/or heavy loads. Electrics are performing these At Armco Steel Corp.'s Middletown Ohio works, approximately 190,000 tons of strip steel are produced in an average tasks as efficiently and reliably as their month. Production of this size requires engine-powered counterparts, while pro the use of material handling equipment viding energy and maintenance savings capable of moving large loads depend, and quiet, fume-free operation in the ably. One part of the material handling process. process incorporates electric ram trucks The fume-free aspect of battery-pow for moving coils of lov.-carbon, fiat. ered trucks, as well as their quieter rolled strip steel for automotive use. operation, have boosted employee morale The largest truck uses a single ram to at the Weatherhead Co.'s Columbia City, lift coils from the temper mill conveyor Ind. plant. The switch to an all-electric and carry them to shipping, shearing or lift truck fleet was made a number of rewind lines. The 60-in. ram can be years ago to help improve plant condi lowered to 14-in. above the floor for tions. picking up scrap coils, or raised to 100. According to a company spokesman, in. for handling full 75,000-lb. coils. the decision to convert to electrics was Armco has used lift trucks in this de a simple one. "We felt that battery- partment for over 30 years and has powered trucks could do the same jobs found that battery-powered trucks meet as other types and at the same time make its requirements for pollution-free oper a significant contribution to our plant ation, easy changeover and charging of environment in terms of reduced emis batteries and sufficient lifting capacity, sions and noise.'' During peak activity, the trucks can be Weatherhead, which manufactures hy expected to run for 20 eight-hour shifts draulic components, processes a million per week. pounds of steel and almost a million At Niles, Mich., Western Electric's pounds of brass each month. The mate Materials Management Center handles rial arrives in long bars 'tthich are han an average of 1.5 million pounds of tele dled by overhead cranes. After the bars phone supplies every day. Prominently Battery-powered ram truck moves huge coils of low-carbon, flat-rolled strip steal at Armco Steal's Middletown works. 4 LIA26856 involved in the efficient movement of all [his material are 22 electric fork lift trucks. The 600,000 sq. ft. facility supplies four A.T.&T. operating companies. A variety of automated, semi-automated 3nd manually controlled equipment ,noves the supplies in and out of highdensity storage racks and bins. But from the receiving doors to the storage input areas and from storage out put to ship ping, the 2,750-lb. capacity fork lifts handle the job. The trucks' work a full 18-hour day and Western Electric re ports that they are maneuverable, de pendable and productive. At Bradenton, Fla., Tropicana Prod ucts. Inc., uses electric fork lift trucks to handle 170-lb. blocks of frozen orange juice in 14-degree below zero conditions. The trucks work 15 to 18 hours a day, up to seven days a week. During the July to December harvest, juice for use during the summer and fall months goes into a bulk freezing system. Frozen blocks of juice are hand stacked on 36-in. by 72-in. pallets, 26 blocks to a pallet, covered with poly ethylene, strapped and conveyed by 5000-lb. electrics into cold storage rooms. In the retrieval process, the bat tery-powered trucks move the pallet loads into ambient temperature where the load is put through a crusher and a heat exchanger that brings it up to 55 degrees. The block then goes through the process that produces single-strength orange juice. R.T. French is using battery-powered trucks to meet the three-pronged require ment of 16-hour work days, reliabilitv and non-pollution in its food-processing Stacility at Souderion, Pa. Here, mustard produced in the morning is shipped in the afternoon, and the afternoon's pro duction leaves the plant the next morn ing. Add to this the plant's output of sauces, spices, gravies and pet food, and the need for reliable material handling equipment is apparent. And with food as the end product, the fume-free opera tion of the electrics is essential. Seven battery-powered fork lifts carry 75 percent of the goods. The trucks do not operate continuously during the plant's two eight-hour shifts, but rather in spurts, coping with two-ton pallet loads. Two of the seven trucks supply in gredients and empty containers to pro duction and take packaged goods from production to shipping. The other five load and unload at shipping/receiving docks for trucks and railway cars, han dle warehousing tasks and help transport goods to and from staging areas. Telephone supplies are moved in and out of highdensity storage racks by battery-powered fork lifts at Western Electric's material management center in Niles, Mich. An average of 1.5 million pounds of material is handled dally. The battery/truck/maintenance/charging area at R. T. French's Souderton, Pa. facility includes an overhead hoist for safe removal of batteries tor charging from the company's electric lift truck fleet. LIA26857 5 128-year-old terne original terne-coated steel roofing to be as good as when it was installed, some doesn't show its age 128 years ago. Terne-coated steel combines the strength of steel with lead's superb corro sion resistance, solderability and paint- ability. Terne is generally mild steel coated with a lead alloy containing When States Roofing & Metal Co. re cently started to restore the dome, about 6 percent tin. The coating is applied to the steel based on the vertical supporting surfaces and circumw eight of the tin/lead alloy per square ferential walkway atop the Alabama foot. For roofing purposes, a 40-lb. coat State Capitol they found much of the ing is usually specified. fflf: hit. Alabama's State Capitol in Montgomery is one ot the most impressive in the country. Much of the terne-coated steel on dome, promenade and supporting drum remains in excellent condition today, 128 years after its installation. Scaffolding encircles Alabama State Capitol dome to enable rooters to partially replace 128-year-old terne metal. Circular drum (Below) which constitutes base ot Capitol dome, also received new "skin" of terne-coated steel. 6 Since the lead coating on the steel not all that thick, periodic paintin * required for protective purposes r B sequently the terne metal roof on th State Capitol in Montgomery, Ala h a been subjected to numerous coats paint in its 128-year existence. Then few years ago one painting contractor sandblasted a number of areas to remove the old paint. This also removed th terne coating and areas of rust devei oped. However, the terne in other areas retained its excellent condition. Because of terne's remarkable service record, and because state officials wanted to restore the Capitol building to its original beauty, States Roofing applied a similar flat-lock seam roof on the dome as well as on the circular drum (or sup. port structure) below the promenade. In addition, terne-coated stainless steel was used in many of the flashing areas be tween the dome and drum section. The terne coating for the stainless supplied by Follansbee Steel Corp,, Fob lansbee, W.Va., is composed of an 80 percent lead and 20 percent tin alloy. The Type 304 chrome-nickel stainless steel used is produced in a condition known as "dead soft." This makes it easy to form with no springback, an advantage in fabricating such architec tural components as flashing and fascias. And, unlike terne-coated carbon steel, the TCS does not require painting. This is a benefit in hard-to-reach areas. The reroofing work on the dome and related areas w as a hazardous undertak ing for States Roofing. A wood scaffold ing had to be erected around the entire dome to allow access and safe working conditions for the removal of old ma terials and preparations of the surfaces for restoration. The work on the dome area of the State Capitol was the first step in a complete restoration of the structure, now designated as a national historical landmark. Well-known restoration ar chitect Nicholas H. Holmes Jr., FA1A, is in charge of the project. Some of our most distinguished ar chitects have, in their time, specified terne for finishing building exteriors. Frank Lloyd Wright, for one, observed that he "found terne superior to other roofing metals in economy, color ad herence, heat reflection, permanence, workability and low coefficient of ex pansion." In addition to the advantages specified by Wright, terne is a highly ductile material which needs no pretreatment for soldering and is just about the lightest satisfactory roofing metal known. Wave soldering of motor armatures provides increased productivity and improved quality Schematic shows position ot commutator armature in half-bearings and its relation to the rotator and solder wave. Cioseup photo shows starter rotor commutator being heated and then soldered by edge shaped solder wave. As armatures are conveyed, caterpillar-treaded belt (arrow) continually and uniformly rotates them. 600 to 800 armatures per hour. Automatic wave soldering is also being substituted for the dip method at Brevel Motors in Carlstadt, N.J., where squirrel cage armatures are soldered and assembled for use in fractional hp motors. In this case, however, the sys tem operates on a carousel type, adjusta ble speed conveyor, and a Hat wave is used to solder the copper rods of the armatures. An operator places the assembly to be soldered on overhanging pins. The assembly is then automatically con veyed horizontally through fluxing, soldering, spinning, cooling, cleaning and unloading stations. The depth of solder immersion is precisely controlled to prevent the solder from entering the center hole of the armature. This elim inates hole reaming which was often necessary when the armatures were dip soldered. Brevel has reportedly achieved production rates of up to 1800 arma tures an hour with this method. The use of automatic wave soldering to join the components of starter production rate and reliability of the soldered joint are highly dependent on motor armatures has enabled automotive the operator's skill. manufacturers to realize increased pro Now most major car manufacturers ductivity and improved quality control. in the United States, as well as Fiat in The joining of the terminals of the Italy, are employing a three-step inte windings to the commutators of arma grated wave soldering system supplied tures for automotive starter motors was by Electrovert, Inc., Mount Vernon, usually accomplished by hand or dip X.Y. The system is a straightline, con soldering. The latter method, most often veyorized operation that includes flux preferred for high volume operations, ing, soldering and cooling stations. A involves automatic lowering of the arma wave of molten solder is pumped ture into a solder bath. through an orifice from a tank, forming Although faster than manual solder a pre-determined shape. In the case of ing, certain drawbacks have been ex commutator armatures, an edge-shaped perienced with the dip method. Exces w ave is used. sive heatsink of the armature when The area to be soldered is pin-pointed dipped in the solder sometimes requires with a minimum of tin lead solder to the use of higher temperatures (up to form a mechanically strong and electric 932^F I, combined with fast copper con ally reliable joint in seconds. Since the tamination and the inconvenient use of molten solder is continuously circulated, inorganic fluxes. And the actual joints-- a stable consistent solder temperature w ire ends and risers--being the last to (650F ) and homogeneous composition enter the dip pot, are the last to reach are maintained. Pre-heating is accom the soldering temperature. And, para plished by the solder wave itself, so only doxically, despite the higher tempera that part of the armature being soldered ture applied, actual soldering of the wire is exposed to the heat. ends and risers occurs at the lowest A caterpillar-treated belt device temperature because the armature has to directly above the processing line rotates be removed quickly to avoid overheat the armature for uniform exposure of all ing. joints to both flux and solder. Rosin In addition, the commutator surface base or organic acid base type fluxes often picks up excessive solder unless are used and solder ratios tend to the costly precautions such as application of high lead containing alloys. Capacity of solder resist are taken. And finally, the each wave soldering system ranges from 3nl U.S. solder forum on West Coast The 3rd U.S. Solder Forum, sponsored by the Solder Manufacturers Committee of the Lead Industries Associa tion, Inc., is scheduled for November 12 and 13 at San ' Diego, Calif. This is the first / program of its kind to be held .`- on the West Coast. The event is , designed to provide a setting erfosan interchange of ideas and technology among individuals plpnssenting various indusiriasthat use soldering as a 5Joining method. As before, the program will feature addresses Vby recognized experts in sol- and technolOne portion will be deJo new developments in iMifaisfing. The Forum is being _w `ed bytheTin Research Inc., and the AmeriWetdtng Society. >y of the program may from Lead Induson, Inc., 292 Avenue, New York, LII26859 Solar-power brings electric conveniences to remote Indian village tv-- !Jt-k mmb k tamamu ik p= umamnai ? v w k mmi The Papago Indian Village, Schuchuli, AZ. is the sue ot the world's first solar electric village power system. This 3.5-kw solar array is providing sufficient electricity to meet the basic energy needs ot the Village's 96 residents. Because of the remote location, power lines have not yet reached many drain on the financial resources of the community. American Indian villages throughout the The solar system consists of solar United States. A solution to this problem panels containing photovoltaic cells. may be solar cell lead-battery powered These cells convert the sun's energy electric systems. One such system was directly into electricity. Lead acid bat introduced last year in the Papago In teries are being used to store excess dian village of Schuchuli, AZ. electricity until it is needed. The bat The 3.5-kW solar electric power sys teries have the storage capacity to oper tem is providing sufficient electricity to ate the system for up to 11 times the power 15 refrigerator-freezers (4.7- daily requirements. The storage battery cubic-foot ), a washing machine, a sew has 2380 AH at 120 volts. ing machine, the village water pump, The Schuchuli Village Photovoltaic and lights for the village's 15 homes, a Power Project was funded by the U.S. church and feast house. The resultant Department of Energy I DOE). The improvement in living conditions is a project is managed by the National dramatic contrast to the quality of life Aeronautics and Space Administration's that existed before the system was intro I N ASA ) Lewis Research Center, Cleve duced. land, OH as part of DOE's National Pho Without electricity, village residents tovoltaic Conversion Program. relied on kerosene lamps for light; Under terms of the Schuchuli coop laundry was either washed by hand or erative agreement, NASA-Lewis fur taken 20 miles to the nearest commercial nished all materials and technical assis facility; and perishable foods and medi tance necessary for the installation of cines could not be stored. Water for the power system's equipment and sup domestic use and for stock was pumped porting facilities. by Diesel engine, which because of the The Papago Construction Company, cost of maintenance and fuel, was a an arm of the Papago Tribal Council, 8 erected the solar arrays and installed all power system equipment. Papago work men also constructed a new domestic services building which houses the vil lage's solar-powered appliances, and an electrical equipment building which con tains the system's instrumentation, con trols and storage batteries. An electrical distribution network, including all w iring exclusive of the actual power sys tem equipment was provided by the Tribal Utility Authority. Dr. Louis Rosenblum, Chief of the Solar and Electrochemistry Division at NASA-Lewis Research Center in Cleve land believes that the application of solar electric technology in the Arizona desert has worldwide implications. "There are more than three million vil lages without electrical power in the world today, mainly in the less devel oped countries,'' he says. "The success of our experiments at Schuchuli is bound to influence the direction taken by developing countries to satisfy the pressing energy needs of their large and rural population." LIAZ6860 Forest lookout towers operate on solar energy Solar energy is providing complete electrical power for the first two solar applications. This battery can store up to 36-kW hrs. of electric energy and of a new generation of forest lookout can supply the tower's normal electrical towers that may replace older structures needs for nearly a month before requir throughout the country's National Forest ing a recharge. System in the future. As a result of the solar energy sys The new, two-story, six-sided struc tem, both the living and working condi tures are located on Antelope Peak, tions of the fire lookouts, who man the 7,600 feet above California's Lassen Na tower on a 24-hour basis, will be im tional Forest, and atop Pilot Peak in proved. In the old tower, lookouts relied the Plumas National Forest, about 55 upon Forest Service supply trucks to miles south of the Antelope Peak site. provide propane for the lamps and re Both towers operate on a 300-watt solar frigerator, while the forest-net radio cell system that provides power for their operated on batteries and water had to refrigerators, water pumps, lights, radio be raised by hand. communications and other small appli Funded by the Department of Energy ances. ( DOE ), the solar electric power systems The system consists of 576, 3-in.-dia. at Antelope Peak and Pilot Peak were photovoltaic cells mounted on 8, 2-ft. x provided by the NASA Lewis Research 4-ft. panels. Generated electricity charges Center through the Tests and Applica eighteen 12-volt lead-acid battery cells tions Project it manages as part of the which were specifically designed for DOE's Photovoltaic Conversion Program. A 330-watt sotar cell system, backed by lead-acid batteries, provides power lor the towers' refrigerators, water pumps, lights, radio communications and other small appliances. One of the two new forest lookout towers that operate on solar energy. 9 It is called the 59th Street Bridge by most New Yorkers although its name is officially the Queensboro. As its name implies, the structure connects the New York City borough of Queens with Man hattan. Spanning the City's East River, the Queensboro Bridge passes -over Roose velt Island, situated in the middle of the River. When it was completed in 1909 the bridge was the largest, longest and heaviest cantilevered bridge ever built, and it remains one of the largest of its type today. Originally designed to carry pedestrians and the Second Avenue ele vated subway as well as trolley cars-- both transportation systems are no lon ger in use--the bridge carries 144,000 vehicles per 24-hour period, making it one of the busiest of the City's no-toll spans. The Bridge is currently being re painted, a task that will take two years and 40 full-time painters. Since the Queensboro has been designated as a New York City Landmark, the final color scheme had to be coordinated between the City's Landmark Commission and the Department of Transportation (DOT). The structure's steelwork will be a tan while its four towers will be painted brown. A brown horizontal stripe will also adorn the bridge. About 64,000 gallons of lead-based paint will be used in two coats to cover the bridge. A key element of the primer is the basic lead silico chromate anti corrosive weather-resistant protective pigment. It is the lead pigment that pro vides a durable and compatible paint that offers superior corrosion protection. DOT reports that lead-based paints have been used on New York City bridges since they were constructed be. cause these paints provide the durability and weatherability required for steel structures. Following the application of the primer an alkyd finish or top coat, also containing the basic lead silico chromate, will be applied. Prior to painting, old paint, rust and dirt had to be removed. Power-driven chippers and wire brushes were used to remove rust and rust scale. Hand chip pers, scrapers and wire brushes were utilized to remove pitted paint, dirt, cement stains and deposits, and oil and grease which had accumulated over the vears. Inaccessible areas, large accumu lations of oil. rust and grease around expansion joints and all other areas were cleaned by a brush-off blast cleaning method. Lead-based paint is applied to steel structure ot Queensboro Bridge. About 64,500 gallons wilt be required to protect the Bridge from corrosion 10 LIA26862 Electric vehicles make hit with U.S. mayors More than 5.000 of the nation's city officials and mayors attending the The latter service enabled 150 mayors, city officials and their spouses to avoid 1978 Congress of Cities Convention ina 14-mile walk in icy rain and reach 5t. Louis last November were given a their destination dry and warm. A fleet first-hand look at some of the electric of chartered buses carried the group to vehicles that are expected to be in serv the parking lot adjacent to the Arch. ice throughout the country in the near At this point 10 electric vehicles were future. Nearly a dozen electrics provided employed to shuttle the guests over the a variety of transportation services for narrow Arch pathways from the parking those attending the event, an annual lot to the Arch's North leg. This was function of the National League of the first time that many of the VIPs had Cities, U.S. Conference of Mayors. ever ridden in an electric vehicle. The electric vehicles were provided Vehicles included: the Endura, a four- by a consortium of interested businesses passenger automobile from Globe-Union, in conjunction with Future Transpor Milwaukee, WI; a converted Dodge tation Models of St. Louis, Inc. (FTM), passenger van and three small four-pas a non-profit corporation which operates senger Electra-Vans from Jet Industries, the only private electric vehicle shuttle Inc., Austin, TX; and six 10-passenger service in the country. trams from Centron Systems, Inc., St. Powered by advanced lead batteries, Louis. Globe-Union's new Maxima sta the electrics provided a number of serv tion wagon was on permanent display at ices for Convention attendees: as an on- the main lobby entrance of the Cervantes call shuttle for shoppers; for tours of Convention Center where the Congress downtown St. Louis; and for the trans of Cities Convention met. An electric portation of VIPs to a dinner at St. vehicle information booth was also lo Louis' Gateway Arch. cated at the Center. Here related litera ture was disseminated to Congress of Cities' participants and questions were answered by representatives of Lead In dustries Association, Inc. (LIA), GlobeUnion and FTM. The success of the electric vehicle demonstration during the Convention was due to the financial support FTM received from a number of corporations that are interested in the development of electric vehicles as a viable means of transportation. In a separate event, members of the St. Louis business and civic community also had the opportunity to learn about the role of electric vehicles in an urban setting at a special reception hosted by FTM at the Convention Center. The reception provided attendees with the opportunity to discuss the role of elec trics in urban areas and to take demon stration rides in the same vehicles that operated during the Congress of Cities Convention. 5 Junta F. Conway, Mayor of St. Loula (Lett) waa among the distinguished visitors to view electric vehicles during the 1878 Congress of Cities Convention in that city. City official visiting ig78 Congress of Cities Con vention in St. Louts prepares to take demonstration ride In Globe-Union's Endura electric vehicle. 11 Lead plates guide x-ray of new aerospace material Collimated scanning radiography provides sharp images when inspecting carbon-carbon composite materials. Cabinet has 1 /16-in.-thick lead lining to protect operator. Synchronized movement of billet and film past two apertures in lead plates permits sharp definition over entire film area. Lead is playing an important role in the development of new aerospace Properties of this composite material plates with small apertures, and a motorare dominatecLby the carbon yams that ^ ffeed carriage to transport the material materials designed to withstand intense form the skeleton. They are much stiffer to be inspected, as well as the X-rav heat, prolonged exposure to sub-zero and stronger than the carefully applied, film. Each of the lead plates measures temperatures and the shock of rapid thermally cured carbon matrix. Because 6-in. by 6-in. by V4'in. thick. The aper. thermal changes during launching and the carbon yarns are subjected to pos tures in the plates are aligned with the re-entry. sible damage during weaving of the pre center of the X-ray beam, thus restrict- For example, lead is employed to form, as well as during the carbon ma ing it to a very narrow angle as it passes focus X-rays used to conduct non trix build-up cycles, it is desirable to through the material. The carriage trans destructive quality control tests of car inspect them for structural integrity. ports the composite material and X-rav bon-carbon composites, one of the new This is accomplished during production film so they are continuously scanned est and most exotic aerospace materials. and in the final form of material, which by the narrow beam. Carbon-carbon composites are replac is called a billet. The beam, actually in the shape of a ing polycrystalline forms of graphite While destructive testing of the mate cone with the apex being the X-ray that have been traditional materials for rial employs standard techniques, the source, traverses the length of the car highly sensitive areas of space vehicle traditional non-destructive testing meth bon-carbon billet, then automatically nose cones, ballistic missile nose tips od was not adequate. Standard X-ray- indexes to the next location and .trans- and rocket booster interiors. Polycrystal techniques required too much time and verses the billet again. This procedure is line graphite has suffered from low ten effort to achieve a comprehensive view repeated several times until the entire sile strength and only adequate thermal of the combination of materials, their surface of the face has been scanned. shock resistance. The newer carbon- arrangement in the composite, the con After finishing one surface, the billet is carbon composites, on the other hand, dition of the carbon yarns, or the posi rotated and the process is repeated until are as strong as mild steel and have very tion and amount of thermally applied the second face has been scanned. The good thermal shock resistance. carbon in each area. Since only a small result is a clearly defined profile .of the Because these materials perform high area in the center of the X-ray was in entire billet, revealing missing yarns and ly critical service, it is vitally necessary focus, the readout was difficult to ana other flaws in the fiber structure. to insure they are produced exactly to lyze. Areas to the left and right of According to the Southern Research specification. In the case of carbon- center were too hazy to obtain a desired Institute, lead plays an important role carbon composites, production steps are reading. in the new X-ray inspection technique. highly sophisticated and the end-result A new X-ray technique called colli The upper lead plate aperture blocks un is a highly complex structure that might mated scanning radiography overcomes wanted X-rays from passing through the be compared to a plaid design in fabric. the shortcomings of standard radiog billet. The lower lead plate aperture stops The carbon yarn space frames form raphy in non-destructive -testing of unwanted scattered radiation from reach the plaid design. The frames, or pre carbon-carbon composites. Developed ing the X-ray film to cause distortion forms as they are called, are filled with by Southern Research institute, Birming and blurred images. coal tar pitch under pressure and con ham, Ala., the new device uses a very In addition to the lead plates, the verted to carbon at elevated tempera narrow, cone-shaped X-ray beam to pass X-ray beams are encompassed in a cy tures. This process is repeated until all through the carbon-carbon composite, lindrical lead shield Vj-in. thick. A sec the preforms are filled to the required thus providing a sharp, clear image over ondary lead shield, 1/16-in. thick, lines density. The final {ffbduct is a skeleton a finely defined area. the cabinet. Both shielding applications of yarns -technically called* a three- The new device consists of:an X-ray protect the operator from radiation. dimensional carbon-carbon composite. source, a collimating system of two lead 12 LIA 268 6 A One-man submarine applies lead's power and weight Submarine's single passenger prepares to close hatch and descend. Lead batteries supply power and lead weights are used for ballast. The $70,000 Double Eagle ll's black and silver nylon envelope, filled with 160,000 cubic feet of helium, stood 11 stories high. For more than 100 years, attempts have been made to cross the Atlantic to get through sunsets, when sudden cool ing causes a balloon to lose altitude. Ocean by balloon. Three Americans To make Double Eagle II as air accomplished that goal in August, 1978 worthy as possible, the crew used a bal in a balloon known as Double Eagle II. loon of high-strength nylon combined Taking off from Presque Isle, Maine, with neoprene, a synthetic rubber that they landed in a grain field in Miserey, resists oil, heat and light. Filled with France over 137 hours later. 160,000 cu. ft. of helium, the balloon Maxie Anderson and Ben Abruzzo, was 11 stories high. The upper portion the two experienced members of the was painted silver to reflect the sun and balloon's crew, had made a previous stabilize the expanding helium as it unsuccessful attempt to cross the Atlantic heated. The bottom portion was painted in Double Eagle I. Larry Newman, an black to absorb heat from the ocean aircraft pilot, was added to the crew for during the night, when water is warmer the second flight because of.his experi than air. This prevented rapid descent. ence in weather forecasting. According to Ben Abruzzo, lead also Lead also played an important role played an important secondary role in in setting the trans-Atlantic record cross the flight. The 8x6-ft. gondola where the ing by balloon. About 750-lb. of the crew lived was designed to be converted metal was used for ballast to keep the into a twin-hulled catamaran-like sail Double Eagle II aloft during the trip. ing vessel in the event that the balloon Without adequate ballast, the balloon was forced to make an ocean landing. couldn't have made the trip. To under A 15-ft. mast and an 800-sq. ft. sail stand this, some knowledge of the basic would provide the power, and the lead fundamentals of ballooning is necessary. ballast would act as a keel for the hull To change altitude, the balloonists de of the craft. Abruzzo says the lead bal pended partly on the gas in the balloon last was in the form of BB size lead and partly on the ballast being carried. shot stored in 25-lb. bags. Some helium gas was released when it As an interesting sidelight, Maxie An became necessary to descend in search derson, the other experienced balloonist of westerly currents. The ballast was on the flight, was recently named the used when a higher altitude was needed. 1979 Copper Club Man of the Year. As In both cases the flight was shortened President of Ranchers Exploration & since each loss of helium or ballast leaves Development Corp. in Albuquerque, less for future up and down maneuvers. N.M., Anderson has become well-known This was a critical factor in the case of in the copper industry for his innova the Double Eagle II's flight since it was tive technological feats in mining and vitally important to have enough ballast marketing natural resources. If you are not claustrophobic, have $12,000 and a strong desire to ex plore the ocean depths, a personal oneman submarine could be the answer. Up in Warren, Maine, George Kittredge, a retired L .S. Navy Captain, has been building these submarines off and on for the last ten years. Kittredge, who is also responsible for the vessel's de sign, calls it "the most maneuverable small submarine available." The basic model is 12-ft. long, weighs about 2,500lb., and can submerge to depths of up to 250-ft. A more elaborate version, which sells for $16,000, can dive 350-ft. Power for both models is derived from 12-volt lead batteries. According to Kit tredge, while heavier deep discharge bat teries would be more efficient, they are less desirable because of the sub's small size. The smaller vessel is equipped with three 12-volt batteries, while the larger craft has eight batteries. In addition, both submarines employ lead weights for ballast purposes. Submerging and surfacing of the sub marine are controlled by three tanks that are filled with water or air to de scend or rise. The batteries power two rotating thruster motors which allow the vessel to move in various directions at speeds of two to four miles an hour. Air supply is replenished by surfacing every hour or so. Important safety features have been built into the submarine in the event that a problem develops underwater. Filling of any of the vessel's three tanks with air would cause it to surface. Fail ing that, 190-lb. of lead weights can be released to make it float to the surface. If the craft is entangled and unable to surface, the operator can open the hatch and escape with scuba gear, including an emergency air tank, which is part of the sub's standard equipment. Ll*268fc5 Beveled glass--A new idea from an ancient art Leaded and hand-beveled glass door and side panels create flawless prism effect and add distinctive look to a home. The ancient art of stained glass has been updated through the use of According to the company, the in creased interest in beveled glass is due beveled glass arranged in a variety of to the fact that today people want the designs, all joined by lead. The shaped look of handcrafted objects rather than glass pieces are joined using lead cames, the artificial look of many materials that or H-shaped strips, with each joint over currently are found in homes and offices. lapping the glass and soldered on both Beveled glass is hand-set in much the sides of the panel. same manner as stained glass. The Beveled Glass Industries, Los Angeles, highly artistic designs are not only CA, is typical of several companies that beautiful, but they are less expensive specialize in producing beveled glass. than stained glass. With showrooms in New York and Los The first step is to bevel Vi-in. or Angeles, the company has earned a rep '/2-in. thick clear glass in the design utation for high quality beveled glass that will be required for each produc products. They include doors, windows, tion piece. The bevels create prisms so tables and architectural accents. that light refraction creates eye appeal rather than color, as in stained All beveling is done by hand, and number of time-consuming steps required for the beveling operation. After the glass sheets are cut various shapes and hand-beveled, they are laid on a piece of paper that serve, as the pattern for the design. The ph**, are assembled somewhat in the sam, manner as a jigsaw puzzle. One section becomes the foundation for another section. After the beveled glass segments have been placed on the pattern, the individ ual pieces are joined by lead earning The earning forms the channel for the glass in much the same manner as s window frame holds glass. When all the pieces have been fitted the lead cames are soldered to tie the joints together. The completed piece is then put into a temporary frame, ready for shipping. At Beveled Glass Industries, more than 500 specially-trained artisans work together, thus increasing productivity. Each worker is responsible for com. pleting a separate operation. The operation has been designed to save time and effort. For example, it has been estimated that if one man were to create a 22-l/g-in. x 66-14-in. door piece from beginning to end, it would take approximately three weeks to complete. At Beveled Glass, the mass production technique accomplishes the task quickly and efficiently in such a manner that many pieces can be finished in one day. Encapsulated lead improves fishing net performance The use of a lead-cored nylon yarn has significantly improved the perform ance of Japanese fishing nets. The new yarn provides the heaviness, softness and water resistance required for effi cient net operation. In order to snare fish effectively, a net should hang as deeply as possible in the water, and show minimal change in angle with tide and current. This is usually accomplished with the use of weights. However, this makes the nets difficult to manipulate and the weights are often lost. And since the introduc tion of lighter plastic nets, the problem of maintaining a suitable fishing angle has increased. One Japanese company, Mitsui Mining & Smelting, discovered that net yarn comppsed of a lead core plastic monofilament would achieve the desired effec Lead-cored nylon yarn has improved Japanese fishing net performance. tiveness. The monofilament is produced by simultaneously extruding nylon and molten lead alloy through a spinning equipment nozzle. The extruded product is then drawn to produce the final con figuration shown in the accompanying diagram. The lead alloy segments are enclosed in a continuous nylon sheath with vacuum spaces in between. These spaces are formed between the lead alloy segments during the drawing process. Dr. Y. Yamanouchi, who heads Mit sui's research activities, reports that successful tests were conducted with set nets made of the new material. These nets are anchored in place in relatively shallow water (about 30 meters). Ac cording to Yamanouchi, the new nets trapped up to eight times as many fish as the conventional type. 14 The Lead Industries Association is a non-profit trade association a representing the lead industry in the United States and Canada. Its membership includes representative firms from all segments of industry and all parts of the world. The Association neither produces nor sells lead, but collects and distributes information relative to the uses of the metaL The services, publications and films of the Lead Industries Association are available without charge to anyone interested in the use of lead and lead products. LEAD INDUSTRIES ASSOCIATION MEMBER COMPANIES Allied Lead, Inc. Alpha Metals, Inc. Amax Lead & Zinc, Inc. Ames Metal Products Co. ASARCO Incorporated 'Australian Min. & Smelt. Ltd. The G.A. Avril Company Lead Products Division Baltimore Lead Burning Corp. Bow Solder Products, Inc. Brass & Bronze Ingot Institute The Broken Hill Associated Smelters Pty, Ltd. The Bunker Hill Company C & D Batteries Division Eltra Corporation 'Canada Metal Co. Ltd. M. C. Canfield Sons Chloride Inc. Cominco American Inc. Daelco Inc. Day Mines, Inc. Delco-Remy Division General Motors Corp. Division Lead Company Dixie Metals CompanyDresser Minerals Div. Dresser Industries, Inc. M. W. Dunton Company E. I. du Pont de Nemours & Co. Eagle-Picher Industries, Inc. Chemicals & Fibers Division East Penn Manufacturing Co., Inc. ESB Ray-O-Vac Management Corp. Ethyl Corporation Federal Alloys Corporation Federated Metals Corporation Aaron Ferer & Sons Company Gardiner Metal Company General Battery Corporation Globe-Union Inc. Gould Inc. Hammond Lead Products, Inc. Homestake Lead Co. of Missouri Houston Lead Company Indium Corporation of America Industrial Minera Mexico, S.A. Industrial Smelting Company Inland Metals Refining Co. Interstate Lead Company Johnson Manufacturing Company KW Battery Company 0. G. Kelley & Company, Inc. Kester Solder Company Lukens Metal Company Metallurgical Resources, Inc. Mincon Corp. Minerals Reclamation Corp. Nalco Chemical Company National Smelting & Refining Co. NL Industries, Inc. Norada Sales Corporation Ltd. Oatey Company Oxide & Chemical Corporation Ozark Lead Company `Penarroya 'Phelps Dodge Corporation Pittsburgh Graphic Products Corp. Powerlab Inc. PPG Industries, Inc, Chemicals Precise Alloys, Inc. Price Metals, Inc. Quenell Enterprises, Inc. Refined Metals Corporation Republic Metals Co., Inc. RSR Corporation St. Joe Minerals Corp. Schuylkill Metals Corp. Sub: Arrow Electronics, Inc Seitzinger's Inc. Tonolli Canada Ltd. U.S.S. Lead Refinery, Inc. The Victory White Metal Company Hyman Viener & Sons Vulcan Lead Products Company Willard Lead Produdcts Company `Associate member FOR CHANGE OF ADDRESS AND DELETION PLEASE ATTACH OLD LABEL. (please check on*) V ATTACH MAILING LABEL HERE Y0 Name, Title Company ________A_________ Street City, state, zip code ADD ME TO YOUR MAILING LIST PLEASE CHECK INTEREST Painting Health & Safety Architectural A Building Design A Radiation Engineers Ceramics Chemical Engrs. Battery Power H Miscellaneou*s`y) LIA26867 15 LIBRARY OF TECHNICAL INFORMATION The following publications and materials are available free of charge unless otherwise noted. Send request to the LEAD INDUSTRIES ASSOCIATION, 292 Madison Avenue, New York, N.Y. 10017 ARCHITECTURAL laad Roofing and Flashing Detailed instructions on in* simplest nc most usual method* for forming or lornmg load for roofmg ana flashing epphcations. Complata specification*. Ongrammattc drawings. Sixteen pagts. A-S Lud in Building A four-pert data thaat containing informa tion on waterproofing. sound darner* roofing and flashing and anti-vibration ap plication. A* It CERAMICS Facts about Ltati Glazat for Art Potters and Hobbyists Detailed information on the proper formu lation. firmg techniques, handling, ate. of lead fluxacf glazes used by art potters and hobby caramittt. Illustrated. Sixteen page*. O-ll Proceedings of First International Conferenca on Ceramic Foodwara Safety Top international experts in ceramics, rood and Drug agency officials, ana the international laid research community met in Geneva in November. 1974 to dis cuss heavy metal release from glazed ceramic foodware. Pull proceedings-- 'speeches t* well as Question and answer dialog--were taped, translated end tran scribed. 272 pages, B-13 PAINTS Laid Pijmtnti Bulletin Brochure. 12-pages, describe* the advan tage* and varieties of lead pigments in anti-corrosion paint*. Covtr* red lead, dtbatic toad phopthita, bat<c silicate white lead, batie lead phosphoeiiiceta. basic lead chromesiiicate. basic lead siheo chromate. List* major suppliers. P-7 CHEMICAL CONSTRUCTION & CORROSION PROTECTION Laid for Csrroiion Reiittent Application! Soft cover book. 156-pages, detigned to tamiliense engineer* and engineering student* with the corrosion resistance, design and fabrication data on lead and lead-based equipment. Define* plumbum series end corrosion resistance of series. H- lead Chemicals Soft cover book. 334-page*, is designed as a working manual for the chemist or chemiea' engineer engaged in applied technology or pure research. Covert organoitad compounds, oxides and hydrox ides. sulfides and tellunOe*, halide* binary compounds, lead salts, lead chel ates. safety in handling compounds. Pur chasing price: S3.00. H-7 SOLDERING AND WELDING Solders and Soldering New 16-page booklet filled with basic in formation on soldering and tha salaction of the right solder alloy for the applica tion. Oate is presented on a variety of tin lead at well as other colder alloys. Sev eral case history treatments of typical soldering applications are included. 1-6 "Solder Puts It All Together for Manufacturer of Zippo Lighters" Two-page reprint from Production Maga zine detail* production soldering of light ers at 2>ppo Mfg. Co. 1-7 Printed m USA. Soldering of Electronic Product! Booklat covars the use of tin laad solder as a highly reliable joining method m the electronics industry. It includes inform#non on the control of electronic assembly components for solderability. fluxes ana flux residue removal, solder alloys and soldering methods i-B SOUND BARRIERS Directory of Acoustic Specialties Summery of available material* for sound insulation by barnar. damping and ab sorption methods. Sixteen page list of materials by brand name and manufacturar. Eighteen pagtt. J-4 Lud i Major Factor in New Mactiinary Noiaa Supprauion Sytttmi Description of techniQuet used to lower machinery noise levels with leed and lead composites. Lists machines that normally excaed noise level allowed by WelshHealey Public Contracts Act. Two pages. Laad Proves a Hesvy Favorlta ai Sound Control Malarial A reprint of e feature from Frwigtot Engi neering illustrating lead's utefdMas m sound attenuation to halp rooit- OSHA hcitejtfiiprement* m factorise and also on a^gpgd trains, i-17 Specifying Laad for Nolle Control Eight-page reprint contains guidelines to help architects and engineers fully utilize the advantages of lead aa a noise control material. A number of cate histories ere included to show how soma of these guidelines were used to solve e variety of commercial. Industrial and residential noiea problems. J-18 Tha Usa of Abtorbar/Barriar Matarialt for Noiaa Control Enclosures Four-page reprint is concerned with noise abatement applications within the 10 to IS dB range, it describes an installation utmg a Quilted ebsorber/toarner enclo sure suitable for achieving these reduc tions. and presents the advantages of this materiel. Acoustical, economic, oper ational and maintenance aspects ere con sidered. 3-19 Tske Freih Look at Noilo Control Two-page repnnt from Modem Stores A Offices explains the usefulness of sheet lead plenum barrier* for office spacs noise control. A case history illustrates th# needs for an acoustical treatment end cost savings realized, j-20 Madam Utas af Laad in tha Construction Industry Thu 20-page booklet cover* significant uses of lead in construction applications, it oeals chiefly with lead for plumbing, waterproofing, roofing and fleshing, antivibretion and sound barriers. J-21 Why Evtryont'i Shouting About Noiee Control Repnnted feature from Iren Age dis cusses the use of sound ebsorping ma terials such as lead to meet increasingly Stringent noise control standards in in dustry. included are simple rules on lead's usa to insure successful applica tion. J-22 Load: A Vital Tool For Induatrlal Noiu Control This 20-page Booklet focuses on the use of lead as a barrier to block sound paths and for dampening structures and aurfacts to reduce vibration end radiation of airborne sound, it deals with applica tions of lead sound attenuation materials and offers practical solutions to noiee control problems. J-23 Laad For Radiation Protection This 26-page guide provides radiation shielding properties, design and fabrica tion information on laad and lead-bastd products. Basic applications lor lead shielding are outlined and current con struction materials and technique* of applying lead as part of a radiation protaction systsm are described end illus trated. K-3 BATTERIES A Primer on tho Leed-Add Battory A condensed story of the principles of the leed-eeid battery and its chemistry, in cluding some of the fundamentals and dafinitions of direct-eurrant electric en ergy. Two pages. L*6 .Electric Work Vahiolai A 12-page foidor describing batterypowered short-haul delivery vehicles and comparing thsir economies to intamai combustion dttivery trucks. L-19 Saving Battery Dollar*--'What You Ntad to Know Thrae-part reprint from Modem Materiels Handling dtali with proper procedure in picking the right battery for the truck and job. It also discusses considerations in battery charger selection. The third part offers guidelines for planning an efficient battery charging-room layout. L-2J Electric Vehicles, Stste-oMhe-Art 1978 New 24*pegs booklet contains latest data on electne trucks, buses and passenger cars around tha worid. Casa histones de scribe EV's in a variety of work applica tions. Other sections cover energy crisis end pollution problems and their effect on EVs; end the ro<e of lead batteries in V development. L-24 GENERAL Primary Laad Production Areas in the U.S. For schools, libraries. Il'xl4* map show ing location* m U.S. of most lead smelter* end refineries, and lead mines. M-ll Tiro U.S. Ltrd Industry An annual reviaw of activity within tha industry that contains a general aummary for the year end e senes of charts and tabiat giving current statistics on lead production and consumption. M-14 Liad--! Modem Design Meterlel Summary of properties and available forms of lead for radiation control, sound/vibration control, electrical energy sources, soldering end ceramics. Eight pages. M-35 Ecology in the Now Leod Bolt Reprint describes cooperation of industry and environmentalists in developing southern Missouri lead minas. Four pages. M-23 Ltadad Gradas: Answer to Free-Machining Needs Reprint reports on benefits derived from using leaded steels tor free machining Ceee histories are employed to demon strate that these t'ades can enable partsmakers to raise production of qual ity components with efficiency *nc econ omy. M-32 Leed end Zinc Outlook 1B76-1980 Booklet examines demand prospects sno Rreduction for lead and z>nc over me next >ur years. Current markets and growth application* are also discussed. 16-pages Occupational Laid Poisoning ... It Naedn't Ba . .. A Manual tor Managers Contems information of uae to the indus trial manager on the safe handling of lead and laad products m industry. Types end permissible levels of occupational laad exposure are discussed. Some prac tical controls and safeguards are sug gested. 16 pages, bibliography, M-34 Load and Your Haalth Brochure contains advice on occupational protection against ovar exposure to lead A checklist of good health oractice* .* included. M-3S Old Paints and Rural Lead Poisoning Booklet discusses the incidence of lead poisoning among children m small towns and rural areas, a problem usually asso ciated with big ctie*. Tha nsed for lead screening programs to detect and correct the problem * emphasized. M-36 Directory of Leed Ceiteri Booklet lists 56 companies throughout the U.S. that produce lead product* for industry. Date on tech firm mciuoes type of casting method, products produced and auxiliary services offered. A contact name at each company is provided. M-37 FILMS Laid in Motion A 21-min., 16mm color film. Lead's prop erties and its potential for unlimited fu ture applications are explored from the viewpoint that an atom of lead--like all elemental matter--is an arrangement of energy--part of a universal system. To order specify desired show date and one alternate date No charge to borrow; ewer pay* oniy return postage. N-2 Occupational Load Poisoning ... It Naadn't Be A 16mm. 15 mm., sound color film, Nar rated by the environmental health experts of international calibre, the film intro duce* the basic principle* of a health pro gram for the lead industry. Tha intention it to motivate the coooeration of both management end employees in develoomg an effective health program for their particular operation To order, specify de sired show date and allow one alternate date. Allow at least five week* for de livery. No charge to borrow; viewer pay* only return postage. N-3 Lead For Nolle Control Audio visual presentation covers leadbased materials available to control noise m n industrial environment. Actual case histories included to document effective ness of these materials. Available as a cassette with slides or e continuous loop 16mm film strip with magnetic audio tape for $15. I1 ii t PLEASE SEND ME THE PUBLICATIONS MARKED BELOW T WRITE IN CODE NO. NAME, TITLE COMPANY STREET CITY, STATE, ZIP CODE TO REQUEST LITERATURE MAIL TO: LEAD INDUSTRIES ASSN. INC. 292 MADISON AVE NEW YORK, N.Y. IOC