SUPPLEMENT TO

FLIGHT
6486

40

JUNE 30,

1938

THE AIRCRAFT

ENGINEER

But the solution of the Structural problems was another matter. It soon became evident that the type of wing construction which had proved efficient in the biplane type was not the most efficient when applied to a thick monoplane wing. Fabric covering could be used, and has been used with success, but the attachment of the fabric to the wing ribs had to be very carefully thought out. For the speeds contemplated it seemed more logical to change over to the so-called stressed-skin type of construction, using light alloy sheet metal for the covering.
DIE HEAD BOLSTER CONTAINER
PRESSURE CYLINDER RAM -i

V///
DIE DIE HOLDER

Basic principle of extrusion press shown diagrammatically. Initially, attempts were made to use sheet strip in much the same manner as was customary with steel strip, viz., by rolling or drawing the strip to the desired section. However, spars as well as ribs had to be attached to the sheet metal covering, and this introduced complications and necessitated a good deal of extra riveting. Thus it was appropriate that designers should turn to the use of extruded sections, the more so as the art of extruding light metal had by then made great strides. When they came to look into the matter they discovered that not only did extruded sections lend themselves very readily to attachment to other members in a simple manner, but the mechanical properties, of extruded metal were Very good, and, what was even more important, they were uniform, due to the fact that in the extrusion process the metal was changed from the cast to the wrought structure, the high pressures employed resulting in the metal being dense and uniform throughout. With their forty years' experience or so of steel tube manufacture, it was natural that Reynolds Tube Co., Ltd., of Tyseley, Birmingham, should not overlook the vast possibilities offered by the extrusion process, and as long ago as 1934 the firm laid down their first plant for the extrusion of light alloys, mainly of the high-strength aluminium and magnesium varieties. Since that time the plant has been greatly extended, and the firm now does a large business in extruded sections, not only for aircraft but for many other applications.

perties for extrusion purposes when heated to the correct temperature, and nine such alloys are in normal use namely, the Hiduminium group, including " 45 " hard and half-hard, " 7 2 , " " D U " and R.R. 56, 66 and 77 and Magnuminium 266 alloy. The factors which govern success in extrusion are temperature and speed on the one hand, and the skilful making of the die and its holder and bolster on the other. The alloy, when being extruded, tends to take the line of least resistance; therefore, in the case of a " T " section, for example, having a thick stem but thin cross-piece, the metal flow must in some way be '' retarded'' in the wide cut of the die and aided in the thin section in order to give an even flow throughout. The dies are made of nickel-chrome tungsten steel of i&in. to ifin. thickness and varying diameter. They are cut in the first instance from an accurate template and then finished to extremely fine limits and highly polished. To give the additional strength needed to withstand the very high extrusion pressures, the die is carried in a dieholder, and frequently an extra bolster is used as well. These are cut to the same contour as the die, but are larger. This assembly is fitted into the die head of the press and pushed hydraulically into the mouth of the container, where it gives a '' metal-tight'' fit. More than 1,600 extruded sections are available, so it will be gathered that the staff engaged in die-designing and production at Reynolds is a large and busy one. The cutting of the dies varies somewhat according to whether the die is to be used for extruding high-strength aluminium alloys or magnesium alloys. For the former the edges of the die orifice are cut square, that is to say, there is no radius or lead-in. For magnesium alloys, on the

Basic Principles
The fundamental idea of extrusion is extremely simple. It consists of heating the metal to a plastic state and forcing it through dies by pressure. In practice, however, a great deal of skill and experience are necessary, as the final result is sometimes influenced to a marked extent by the selection of the right combination of temperature, pressure, and die shape and finish. The Reynolds Tube Co., Ltd., has by now had four years' experience, and its products have become recognised throughout the industry. The first patent relating to the extrusion of non-ferrous metals (the process has been employed in the lead industry long before) was that granted to Mr. G. A. Dick, of the Delta Metal Company, in 1894 f r the extrusion of copper alloys. The process remained the monopoly of that company until 1914, when the patent rights were waived to make the process available generally. Aluminium and magnesium alloys have suitable proThe lower photograph shows the complete die assembly, while above are shown the bolster, die-holder and die. other hand, the faces of the die orifice are radiused. There are several interesting points in connection with these dies. Small sections are produced several at a tune, and such dies are referred to as of multiple-orifice type' When extruding tubular sections use is made of a mandrel centred in a hollow billet. The tubes are afterwards c o W drawn down to finished sizes. Solid sections are extrude" to their finished size. t At Reynolds' Tyseley, Birmingham, works there are, < ^ present, five hydraulic extrusion presses. Three were ma by Fielding and Platt, and are 750-, 750- and 2,000-to