COMMENTS ON SOVIET PAPERS ON CONSERVATION IN THE USE OF METALS

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• Document Page Count: 8
• Document Creation Date: December 27, 2016
• Document Release Date: March 13, 2013
• Sequence Number: 88
• Publication Date: June 25, 1953
• Content Type: REPORT

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CENTRAL INTELLIGENCE AGENCY
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Comment:son S,wietPapereon Conservation
? ^ ?
mCwM.A.12.
DATE ACQUIRED
DATE (oF taro.)
611.?.? CAM 51.1 .5.01111.?? 150 ?O?lf.t.?? ????5??
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ems /Os ?? ??? ? II Ct. at 5?????.51.5? 54.
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THIS IS UNEVALUATED INFORMATION
DATE DISTR. 02.5. Vat/a
NO. OF PAGES 8
O. OF ENCLS.
SUPP. TO
REPORT NO.
lbo
Titles
1. _Yki chno10 of Periodic Shapes and the Connervation of Metals.
2. Rational ,Asoice of Malmrials for Machine Construction
3. _II-Porlazesia_I==_EL Factor in Conserving Metals mad Lowering the Cont of
Producinf Parte.
4. Repeated Reco" ltloning of Worn Tools
5- cclumrvatl'--1 Of-tta44-1E2SZELLEaEl.1
6. Uttlitation Coefficient of Wrought Ferrous Materials
3
6
7
1. TA.U.;40 ar.i.a V. Ap4..vagLwaL: .flew Technology of Rol-sing Periodic Shapen and
tJir, Coacer-wation of Metals. pp 24-3:).
G. 7we tylK:b of parts reem perticularly suitable for production by menan
of roll periodic shaper: axles and eimilar parte with a round nection,
r.L.cd only machininF after rolling; crankehafte amd other parts
that do not have a :mind rectioh, 'when, the rolled nhape must be (mese-
que.1.:,1y forged.
(1)
The main rdvantaKe of tnic process in the decrense in production
conts and e-oanunptioa of teel resulting from the fisct thAt
iparto can be furnished closer to finial dimennions than in feanible
with forgings. The amount of nteel lowed varies from 10 to 25% of
that neceeeery with previoun prose/suing methods (gencrall,y forging
or preening).
u. S. of..cieln only
CONFILENrLAL
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(a) For example, 3.6 kg of steel were required for e drop-forged half
axle but only 2.9 kg for the same axle GZ rolled by the new proceaa.
On thio basic, a eingle [stand prodecing 12,000 tons a year would
save 2850 tons of steel a year.
b
In the cane of railroad axles, the weight for a her forging is
560-500 kgefor a drop forging 510/520 kg,and for parts rolled by
the new procese 46/1-470 kg. Therefore, 7000/9000 tons would be
caved in the production of 100,000 parts.
(2) The properties (apparently in the ae-rolled condition) of the finished
part are taco superior to those obtained with previous methods or pro-
cessing.
(3)
Additional advantager of the new process. are ease of changing from one
s'ze to another; rousibelity Cf co=plfite meenanization; lower operating
costa; leas wear and mantenance.
b. Several models of etanue for roLling periodic shapes were made commercially.
Despite the technological and eeonomic advantageo of thin proceos, itb
adoption by induetry has been very slow.
( 1 )
One stand was installed in 1951 in r factory making textile mftehinery.
Although approximately 40% less, eteel was needed for each apindie, other
factories In this field have -lade no attempt to time the new process.
(2) In Sestember 1952 a larger unit for eeteeotsle parte was completed fur
a Moeeow plant, which hart not even ntarted to inctaal the eoulpment.
Several thousand axles have, however, been by the new process for
Moakvicn and Zie automobiles. Tnese axles proceoped natisfactorily
and are now In service.
(3)
A still larger t'tand wae deesgned ror one of the metallurgical planta.
Wor4 on this model woo diecontinued, however, since the Miratry for
Ferroea MetallurFy showed no interest.
c. Mia method eceedo like a type of roll forging. /n general, this proceAa
arse not been used widely here bocauee of the high coat of relle and the
few a!vantageo over modcrr forging Cr not extrualon methods. Y)rd, for
exemple, mekea airsilnr oarss to acee of those deocribed in the present
paper by hot extrusion and c2ulx..5 various advantages over forginga.
C L Stever4 ahd G Vennernnlm: The Application of hot Extruniot.
Methode for Automotive Product:on. SAE Preprint 269 (1949);
an abstrn.: war public:led In SAE J 51 (1,j1.9) mo. 7, p 43.
d. Thin nietz.c,U appeare to be a nerteer develcpmcnt of the method deecribed by
AiQkramdrov pee Yuciovien in 1,446 a.. satiefoceery for certain tank shafta.
Le this the roiled shape vac used to eliminate the first of two drop-
forging operatione.
anu c, Xi0ov c . I n trmittc:.t Shapes for Drop
Torgine Stabilicer 3hafts. Stal u (1946) pp ',59-565.
e. There col.ld he variouc excuLec for the delay fr,c. September to December
In Installing the one unit. en the other Land, If the advantages mentioned
by Alekeandrov and Yudovice were legitimate, it is aurpriaing that this method
hen apparently received so little recognition by induntry in the period from
1e46 to 1_552. Pernape seme of tne disadvantagea m'ntioned under C above
were a factor.
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f. The difference in viewpoint among the varioum ministries and buecaes ic rather
intereotine. Apparently the departmente dealing with the design and construc-
tion of new eqeipment have considerable initiative in developing new processes
even when the departmento and mimistrier that must use the reeultant equipment
are neither enthusiastic nor interested.
! 9
V
a. The old idea that cafety depended mainly on mass has been shown tn 4n
11
correct. The fifth five-year plum eello fae etereace in weight of reehtneo
and an increase in perforeance in addition to a doubling of production. The
availability of a vide variety of materials and the poccibility of using each
where it in tot Suitable fa=llitate the proper choice cf material/5 and open
the way for nev designe with higher performance and lover weight and cost. A a
careful analysis of each mart ic needed for best results. National econce7
as jell as technology and production meet be couaidered. In =any canes the use
,f relatively expeneive maLerials will give better performance, Inver weigat and
lower over-all costs than could be obtained with a 7.2-.eaper material.
A comTarioon of the performance and weight characteristics of precent machines
with thooe produced a number of years ago ()hove what has already been done
along this line. Attention 15 called to tl rerits of varioue materialn and
prate/men:
(1)
Alloy and inoculated cant iron, which io often more econorical than wrought
steel. Examplen given include crankenafen of internal combuation entAnia,
cylinder blocks and machine tools. Particular emphanin in placed on the
aut.-ability of inoculated cast iron for MIAAD production (cane of mechanis-
ing foundry, excellent machinability, high yield of nound parts). The
use of cut iron for cylinder blocks in the automotive and tractor in-
dustry, for example, =ohne the saving of hundreds of thousands of tone Of
wrought steel.
Steel cautinge, especially thoce produced in smallEeocemerc.
Cold pressed steel sh,l.et. Ac shovn by ceveral parts of the 7.IS-150 auto-
mobile, the substitution of cold pressing for hot forming permits the use
of thinner nectiono vitt. a resultanL weight caving.
Alumirum and naeresfun. Par tc on of theee metals and alleye are lighter
In weight and cacdr to machine than equivalent parts of weought steel;
Bimetal:: or cceee)cite mrtalc, el:Ich frequently permit marked oavingn of
r,orferrL;u41 bUCi. al, bronze.
Powder ..letallurey, the applicutior of which io unfortunately limited I
by the relatively hieh cost of m,t-Al powders, the impoeeibility of
nahiLF heavy parts 4T.4.1 'the fact that powder z4tallv,rgy is not economic
for smi1e/lc/11e 1.roductf.on.
(7) P1,rticn
(3.) Cera=1
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b. A cazual reader would be inclieed to question why there was any uee of wroueht
steel or weldments. Although there Is a casual statement that such materials
may be suitable in some ca-eo. the entire emph,,sis is on "new materials. This
may be intentional in an effort to induce designers, engineers and economlete
to think about unconventional materials and proceesing. (It is perhaps note-
worthy that this paper 15 preeented "for cliocusnion".) From an unbiaaed view-
Although the high propertlt.J that can be ootained with alloy and heat-treated
steelz are mentioned at the _tart, 'hey are igeered for the rest of the paper.
While the author feels, and reme englosers here would agree, that east Iron is
superior to wrour-steel weldoecte for many applicadone such as machine tools,
other authories authoritle27 could cite cases to prove the reverse. Crokult
does not emphaaise the clone coanectioh between design and choice of makrria3s.
Actually a comparioon of the suitability of caet iron an welded wrought steel
is completely valid only if the des16,71 ih each ease has been ouch as to take
advantage of the particular propertlee of the type of material to be -Iced.
c. The diecusuion of the various materials lc mcre or less in line with usage in
this country, although the space and praise given to cast iron appear octmeerhat
dieproportionate. The persistent mention of inoculation is ratner odd, since
inoculatio4 is now accepted here an rt matter of course in the production of
nigh-strength cast iron. Gokun may, however, have wanted to emphosite the
auperior.ty of modern cast iron to the older product. No mention le made of
nodular iron, id.ich .as received much publicity here and in Europe in the past
few years, altaough the maximum tennile otrengtn or 114,000 psi mentioned as
eeing obtainable with coot irct see= to be too high even for alloy or heat
treated gray camt iron.
3. Illissaatax Powder Metallurgy as a Factor in Conzerving Metals and Lovering
the Coot of Prcducing Parte. pp 40-45.
ft. A general diocuzeion of thectonomies !* powder metallurgy and Its present
status in the US5R. Only passing mention is made of special products, ouch
as olntered carbides, that can be mad* only by powder metallurgy.
( 1)
The bizic e :monde advantagee of powder metallurgy for UMAO production
are the use of cheap waste prodacts instead of highly proccocea materiala,
and the lowered .7ohrumptlor o: eaterials resulting frost the prectical
climinatiDn al ma.:hlrAng arrl th,r lighter weight of the finiehed parts.
Even when epeTlally proceed 7.etal pevderc are uced, the cost of produc-
tich Ic lower than w1t1-2 wrough- produto- in many '-aces labor costs are
cheaper vitt pevder retallurgy beceuro lent, skilled workere con be used.
An extensive development of powder metallurgy woule make popeible the
conservation o: a large ..r.runt of metal each year and would add mile?
rtentially tc the mate:icl rencurcen of the USSR.
(2) The maln materiale that come into questln for maze-produced parts are
Iron, come tyTen of alley steale and copper, all of which can be obtained
erom waste products, re..-h es, mill cra120 duet, turnings and chips. The
rs-overy of euch waste prodli7tr tic powder is far more efficient than their
utilization `,r remelt:ng. It s Ortmn poL,.elble to nunititulx cheerer
materials (fc Lep on,:e instead of tin) wit,n powder-metallurgy parts
are Gub5titutcd for wrought p:oducte.
(3)
A table In eiern to illuntrnte the amount of material mnd =no-house re-
quired and the ccrt per plece for ni-Jr. ty-ix.r of pnrtn, as produced by
mnchinl:Ig nnd by powder metallurgy. In eentral. cn-h ton of parte pro-
bY Pouch'!" m'7"11:;re:,:y :?av,:i up to twe tnr3 of proccerted metal and
up to 10,3,00 1:curr, of :miarhfrinv,
(4) Powder metallurey mIT,!ady lo-e4 for :In'er,:.d cart,;(lec, high-melting-,
metals, ,opp,,- tnr, reeifrt:tIon pee's and mAFT.tn. On the othef
:taint
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lagatd, the coomercial maas production of iron-bane ;arta by powder metallurgy
ia practically nonexiotentbecause of the underestimation of the benefits of
thia method by the varieum'mlniatries.
(a) The Ministry of Ferrous Metallurgy has been studying the problem for a
number of years but ha z still done nothing about the extenalte production
of iron psTter.
0)) Deupite the pramtcIng work by prgmvtomran on ,ertain tyoes of parts, there
is no commercial production of powder-metallurgy parts for the automotive
and tractor induntry.
(e) The Mloictry of Hrmo;.- lodustry nar made no provision for the manufacture
of iron-graphite bearangs in spite of their uuccesofu.l production on a
Laboratory scale. Subitantially the same lack of progress is found in
the Minletry for the Construction of Machinery. and Equipment.
(d) Moreover, the production of the occessarf aotomatic pressing equipeent
and electric sintering. furnaces ir either nenexistant or innufficient.
The one exception to this dismal picture in the Ministry for Coal Produc-
tion, which baa organized the production of Iron-baae bearing and other
parts in a relatively Short time.
The nteps that should be token for commercial exploitation of powder metatletilgy
fOr mass-produced parts are outlined.
(a) The suitable industrial basis for the proc..(ction of various types of iron
powder should be created. Automimation (?) mould be consiocred here aa
it would have the edded merit of lever:Le the cont., electric energy coo-
nomption and manufacturing space requiremcntn of powder(' for other porpoise?,
ouch as ferroalloys for welding-ele,..troie coatihga, which are now produced
by ball milling.
(h) The ministries zoncerned should begin to make ruitable equipment for powder-
metallurgy production (automatic pre',cen, zintering furnacec).
(c) There nhould be a catio*actory al..ocatlur. of the typcn of part:. 'to be produced
by each .7.1ni5try.
b. The figuren in the tnole, which 4u 6iveh fc: ?1(ctratl:e purpOneu only, mean very
Itttle wIshout ether detailt, n4ca an th Taxt: produced.
C. In the USA, =any of the part:- -?Ade eon 1rn pcvc,: h-ve denrities approaching that
of toe wrought prociuct. The =ehtion of oter w.-!IGht of finirhed producta would ?
(c..y z.pre -,neeineL wltn rout par4c tt'nn wIth "high-denzity" iron-
povde: pcstu.
d. Lh,ovskly .3 -ov:.7'uLly a cohvi.leeu a4vccate c: m-talltrgy for mass-produced
iron-bae part.. :rom the lacl. of intrcLt airpla-jeu co. most of the mlnistrica, it
iv clear that no ha:" hct gotten fa: 1.r.t. hn ,..4-0.111zntL. Thi: nay ttxplai. the emplianiu
placed on the ore of "warte proloctr" an a Lc-rce cf oowler. There to considerable
doubt tnat would 111,- fc: a11, a majority, of the applica-
tion:, where 1: ,owler coald be Wed.
In the 'JA, iron powde: iv made by var:oun pr,ce3tee, iLcauding reduction of mill ccale.
(An fax Ld 1 onIo, . and iuru are rot uca or'.) Du Pont and Fulton
f the ?lactic PretnIn Div of The National Radiator Co., ,x major producer of Iron
powder, have written:
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"So no dingle type of powder will fill the bill. To provide iron powder
on a tailor-made baaie for .-eich application, the producta of the five
fundamentally different production methods described in this article
are frequently mixed...
"Numeroun companies have been unsuccessful in the production of iron
powder. This is due to their failure to recognize one or more of the
following facts: (1) No matter how cheap an iron powder may be developed,
If it done net have the required properties it cannot be cold profitably
in large amounts; (2) conversely, no matter how well a grade of iron
powder eight meet ell quality specificationr for a given applieation, if
it cannot be produced to be cold profitcbly at a marketable price, the
demand will disappear; (3) noewithetanding the oubstantial increaaea in
the demand for many types of tron payler, the iron powder industry in
still a relatively =all one."
B T DuPont and R Fultcn: Five ways to make iron powder. Iran liaz
169 (1952) no. 17, PP 135-139.
Despite the street; Rakevekly places on tne precured cheapnesa end economy of
powder made from waste producto, he tacitly indicates the fact that ouch
powder cannot be uned for mll purpones when he refers to the need for pr..-
dueing varioun typal: of powder. Therefore, there does not appear to be much
diffetence in concept between the USSR and here, although Rakovokly'a paper
would indicate tlat the scale of production of iren-bose parts by pentdor
metallurgy is far smaller in the USSR than it 1$ in the UBA.
4. I../.2Alasklau. Repeated Reconditioning of Worn Tools. pp 72-74
a. Brief discusnion of reconditioning toola at Vlediner Il.ich 1,3,4g1; organiza-
tion; routine paper York; dioposal of tools that cannot be reclaimed; methoda
of reconditioniug, inapection of leconditioned tools; plena for future improee-
menta in department. During 1951, 22 tone of tool ateel and about 126,000
rubles, were saved by reconditioning. In aadltion the man-bourn needed per tool
were decreased by 20-25% tei compa:inon with new tools. The lavortance of auch
reconditioning ic oleo shown by the fact that tool consumption amounts to
about 101 or more of the :let cost in the conatrection of machinery.
b. The methe4a used tor reconeitioning appear normal except in one case. A 'bard
alloy" la electrolytically depo5lted on new at well as reconditioned tools to
improve performance. At present, the thirkness of thit, coating in 0.002 in.,
but tin., equipment will petit an increase to 0.00C-0.012 in. The nature of
tbie coating is not Indicted. A113?, It is not clear whether this coating
supplements orireplaceo cyaniding, which is sa1e to be used on all high apeca
steel cutting tools. Cyaniding is cor=only uzed in the USA on high speed steel
cutting tools but without an elcctrolytic coating. Chromium plating in ueed
to a lesser extent, with thickneen-n about the same an those mentioned by
Yaktmehuk but in that case It it. nct 2car why he refers to the coating AA
"hard alloy' and not aa chromium. one proprietary process that has found a
certain 3opultuity id the UBA for tools ("Eaectrolising") is bowed on the depo-
dition of "an extremely ward, dense alley", but the thicknesses are conaiderably
less than these given by Taklachuk. The nature of Eletrolieing has not beet
dieclosed but it in being ueed by Y.710110 well-knawn companlea ouch as More?
Twist Drill end ?chine Co, Lapointe Machine Tool Co; Tatt-Peirce Manufacturing
CO.
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tmllcyjaz_gag_jat.tleov: Conservation of Metals in Repair Work. pp 74-77
a. Among the metbods uved by the Moecow Brake Factory to conserve the atoznamt
of mat-rial needed for maintenance and rel..,.tr of lathes and other machine
tools are:
1. Chremlum plating
2. super!ic1a.1 inductioa hardening
3, modernization, aE by rebiaeiec
ueetil.e bearings'.
4. use of "compensation" tuchinc? em pou-tc cuch as seara
5.improvement in design, as by Increasing fillets
o. stancsareication of replacement nate, Including a
aecrease in the number of sitee needed.
7. decrease in machining allowances
8. rebuilding worn parte by hard surfacing, chromium
platime or weIdin6.
9. sh,ot peer.ini? or burnishing ct gears.
Most of thee mesaures are designed to increatie the year resistance and
durability of individual parte. During the pet four yearn, tUese measures
have made it possible to decrease the &mount of material needed for main-
tenance and repair by the following amounts
1. engineering carbon teels by 27$
2. low alloy steels by 21%
3. cast iron by 16),
4. nonferrous castings by 60%
b. The authors ntate that mainte.misice of a lathe during Ito life requires
several times nuch metal CID VOUid be required to build a new one. This
etatement aounds root peculiar and wculd tend to indicate either an unusually
large amount of reptile work. necessary or an extremely long life involving
several rebuildings. It would be a rc:lection on the conatruction of the
lathes if these mc.thods - or at least some of them - were not used in the
original conatruction. Since the .?-t.,,ern inainuate they were not, it in
possible that the lathes r enlderation wcye either poorly made or
very old.
c. The measuree taken to preyer.t or einimize wear would be considered liOrmal
here, altho4gh they pronatiy would not be deccribed nOthade of conserving
metal but rather ac moftne of rrolongthe service life emu improving perform-
ance.
t. co. the whc;e, t-.t ?71. of paler that night be written hero
by the chief mocnani, ,L, head th: preventative maintenance
department itazzlia) an.1 alc. i?T .1. 4 il r,..cn as American Machiniat.
6. . "it attcn:
a ?
The '1'11:eat-on coeffi,l-t..
e!f:t.enzy of utilizatIot.
It .1, ottained ty dividirg
rolled ttcc'k nercTsftry To rA):
affect tLi... index are
Thcr, fore th= f-oeffirtvw.
Ice.our, enchi:.-o or pkf',.
tLe offic1en-1 of rport1,,
1....tcrials. pp 52-el
ne .f The tall,: ...dices for determining the
,n he-hInen unc engineering construction.
- weIght f he Pi:Ached part by the weight of
, that pqrt. Two of the factors; that markedly
:ly of pnr? and type of rolled product involved.
-'it. to u-ci only to tw..pare Or 'ADD ana-
sy ate, ,oweyee., 4ery useful in considering
rnT.onr. exaLple, Ir. one automotive plant,
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50X1 -HUM
imprnvelreets in lay outs for sheet increased the ntiliration coefficients by an
average of 5j,. In the Cabe of forgingo there out to be two coefficiento:
one to show efficiency in the for :thou; the occond, efficiency in the Aachina
chop. An analyula of the various types of loso_o will indicate pocoible ways to
increase efficiency.
b. The utilization coefficiento mentioned in thin paper appear fairly reaoonable.
automobil.= 0.66-0.85
tractors 0.62-0.70
comprc000rs 0.49-0.60
oachine tools 0.44-0.50
freight cars 0.92-0.96
ohect and plate conetruction, as for
re.ilroad care and ships 0.90-0.97
parte made fro= bars ana forgi.ng 0.50-0.70
bargee with load capacity of 2000 tone,
where barn or lorgingo represent leas
than 3 to 4% of oteel and about 96%
in sheet or plate
ZIS-150 track
:urgings
over-all for rolled woducts!
0.97
av.:r0.2
0.72
scare made from bars 0.1,5-0.f30
e nvt clear whetner thio applies to ZIS-150 truck or
Z3 -150 automobile
c. Thcoe utilization coefficient:: lepresent the maxinur possib.i.c. output and do
not to. .Jjectione into consideration. Therefor, they would be uncful as
an indicntion of the hIgheot production that collie be obtained from a given
otecl. Although the poroibility in not menticnca, such coefficients
-ubtedly be uneful to ?:entrol nlannern ir setting up production soc4a
:leek on illegsa dive:clot: of cteel.
I Declassified in Part - Sanitized Copy Approved for Release 2013/03/14: CIA-RDP80-00809A000500090088-3