Slashdot Mirror
An 8,000 Ton Giant Made the Jet Age Possible
Hugh Pickens writes "Tim Heffernan writes that when 'The Fifty,' as it's known in company circles, broke down three years ago, there was talk of retiring it for good. Instead, Alcoa decided to overhaul their 50,000-ton, 6-story high forging press, now scheduled to resume service early this year. 'What sets the Fifty apart is its extraordinary scale,' writes Heffernan. '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.' The Fifty could bench-press the battleship Iowa, with 860 tons to spare, but it's the Fifty's amazing precision — its tolerances are measured in thousandths of an inch—that gives it such far-reaching utility. Every manned US military aircraft now flying uses parts forged by the Fifty, as does every commercial aircraft made by Airbus and Boeing making the Jet Age possible. 'On a plane, a pound of weight saved is a pound of thrust gained—or a pound of lift, or a pound of cargo,' writes Heffernan. 'Without the ultra-strong, ultra-light components that only forging can produce, they'd all be pushing much smaller envelopes.' The now-forgotten Heavy Press Program (PDF), inaugurated in 1950 and completed in 1957, resulted in four presses (including the Fifty) and six extruders — giant toothpaste tubes squeezing out long, complex metal structures such as wing ribs and missile bodies. 'Today, America lacks the ability to make anything like the Heavy Press Program machines,' concludes Heffernan, adding that 'The Fifty' will be supplying bulkheads through 2034 for the Joint Strike Fighter. 'Big machines are the product of big visions, and they make big visions real. How about a Heavy Fusion Program?'"
Modern planes, and other transport/engineering structures, are moving to composites. Which are layered, printed, sometimes pressure baked and squeezed into form. But no longer forged on this scale.
While these machines are awesome, I've wandered along a car body stamping line and watched plates go from a flat sheet to a car door in 100meters, they are becoming less necessary to us. They will still be needed, of course, for some jobs where only such a monster can help, but I think the US should look on these as potential future museum pieces, with nostalgia for a bygone age of megaengineering, rather than a source of future industrial dominance.
"Oops, I always forget the purpose of competition is to divide people into winners and losers." - Hobbes
It IS the blender.
rewriting history since 2109
This is another score for the government and a blow to the idea that provate industry always does everything best.
Some things are simply too expensivre and farsighted for private industry to invest. That's why a decent sized government is needed, to invest massive sums of money in things like this giant press. It has paid back massively.
SJW n. One who posts facts.
"The Fifty will soon be supplying bulkheads for the Joint Strike Fighter"
I'm not a big fan of dumping more money into the military when our science budgets are so thin.
Join the Slashcott! Feb 10 thru Feb 17!
No, a large rich arrogant country with a lot of infrastructure built around its standards that would cost a fortune to change.
Maybe... remember that Boeing only delievers between 300-500 craft per year with order lead times of several years. I suspect that Airbus is similiar. With that much lead time and low numbers, its possible they forged those specific parts ahead and Boeing/Airbus held them in inventory. In fact, that would make sense given the tooling and setup on a machine like this, because it would be cheaper to do a large production run of a certain quantity than to forge each item 'just in time' and have to re-tool for each peice or seperate run. So, its very possible, and I would think likely, that every one really does use parts produced on this machine.
"It makes me sad that now there are some things that the US can no longer make."
We can make anything we used to make, and many never before made.
It's just that we are led by weenies ( politically and economically ).
And that is what there is to be sad about.
emt 377 emt 4