SQUEEZING OUT THE “PIPES”
Steel for guns and armor is made in the open-hearth furnace where the quality of the metal may be regulated to a nicety. Gun tubes are cast in vertical molds and during the cooling of the ingot it is subjected to pressure so as to prevent segregation and the forming of “pipes.” Pipes are cavities that are liable to form in the center of the ingot due to contraction during cooling. Steel, as we have learned, is not pure iron, but an alloy, and the various constituents have different temperatures of solidifying, consequently they exhibit a tendency to segregate. It is to overcome such tendencies that a so-called “fluid” compressor is used. This is virtually a hydraulic press with a plunger that bears down on the fluid metal as it is solidifying. Modern big guns are enormously large. A sixteen-inch 50-caliber gun, for instance, is nearly seventy feet long, consequently the ingot must be even longer than this and the fluid compressor for so large a piece must be correspondingly powerful. After the ingot has been cast and cooled, the ends are cut off and it is bored to form a tube. Then it is placed in a furnace and raised to a white heat, after which a bar or mandrel is inserted in the bore and the tube is placed under the hydraulic forge press. This is a very powerful machine with an immense hammer that is actuated by hydraulic pressure. The stroke of the hammer is carefully regulated so that the forging as it is turned in the forge is subjected to equal blows. In the forge the tube is roughly formed to the dimensions it is eventually to have when finished. The process of forging subjects the metal to strains which must be relieved and so the tube has to go to the annealing oven where it is raised to a temperature which destroys crystallization. In this oven it is allowed to cool very slowly, letting the molecules of the metal adjust and rearrange themselves. When the temperature of the tube has been lowered to a certain point it is taken out and plunged into a bath of oil. This sudden cooling tempers the metal, giving it a high degree of elasticity and tensile strength. Again the tube must be annealed to relieve it of any strains occasioned by the tempering, and then it goes to the shop to receive its finish boring and turning.
The process as here briefly described seems simple enough, but we must not forget the enormous size of these pieces and their tremendous weight. They would be difficult enough to handle when cold, but much of the work is done while the pieces are at a white heat so that the men who control and operate the machinery that handles the big forgings must keep their distance. The casting, annealing, and tempering operations are performed with the piece in vertical position, and lofty machines and cranes are required to deal with these tall castings. A visit to a plant which manufactures big guns is bound to impress the visitor with awe and give him increased respect for the men who are able to handle such huge masses of metal and also for the men who have conceived and developed such gigantic operations.