Sunday, February 12, 2012

The Fifty


The Atlantic highlights Alcoa's 50,000 ton forging press, located at the company's Cleveland Works:
The Fifty, as it’s known in company shorthand, broke down three years ago, and there was talk of retiring it for good. Instead, it was overhauled and is scheduled to resume service early this year. One of the great machines of American industry has been reborn.
A forging press is—begging the forgiveness of the engineering gods—essentially a waffle iron for metal. An ingot, usually heated to increase its malleability, is placed on the lower of a pair of dies. The upper die is then gradually forced down against the ingot, and the metal flows to fill both dies and form the intended shape. In this way, extremely complex structures can be created quickly and with minimal waste.
What sets the Fifty apart is its extraordinary scale. Its 14 major structural components, cast in ductile iron, weigh as much as 250 tons each; those yard-thick steel bolts are also 78 feet long; all told, the machine weighs 16 million pounds, and when activated its eight main hydraulic cylinders deliver up to 50,000 tons of compressive force. If the logistics could somehow be worked out, the Fifty could bench-press the battleship Iowa, with 860 tons to spare.
It is this power, combined with amazing precision—its tolerances are measured in thousandths of an inch—that gives the Fifty its far-reaching utility. It has made essential parts for industrial gas turbines, helicopters, and spacecraft. Every manned U.S. military aircraft now flying uses parts forged by the Fifty. So does every commercial aircraft made by Airbus and Boeing.
This was part of the federal government's Heavy Press Program, a Cold War initiative to keep us up with the Soviets.  The story explains more.

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