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Reviving the past

May 15, 2003

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When he looked at the outside of his building, Bellingham, Wash., YMCA Director Dave Harding realized he faced a challenge.The original Bellingham, Wash., YMCA building.The YMCA's main downtown facility was located in an early-1900s, four-story building. In recent years the interior had been...

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Brazing copper tubing

May 15, 2003

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Torch brazing copper tubing is one of the most common–but widely misunderstood–joining processes. It's possible to make sound joints that are just as strong as the copper tube, easier to braze, and less expensive to produce. But first you have to know basic brazing concepts, including joint design, filler metal behavior, and metallurgy.

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Examining slit coil handling and packaging

May 15, 2003

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While it is common knowledge that slit coil handling and packaging often limit the productivity of even the most modern, high–speed coil slitting line, coil processors generally spend too little time examining the effectiveness of these operations.

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Employees value workplace health and wellness programs

April 24, 2003

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Sixty percent of respondents to a recent survey consider health and wellness programs a viable incentive to stay at their current jobs. But it must be the right program, one that addresses the employees' concerns.

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Tube Hydroforming Design Flexibility—Part III

April 24, 2003

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The last article in this series noted that variable periphery design, or cross-section expansion, often is thought to be the most important aspect of tube hydroforming design flexibility. Expansion in the hydroforming die commonly is assumed to be the most efficient and most effective method,...

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Siege planning or strategic planning

April 24, 2003

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"Globalization isn't news," said Lawrence J. Kendzior, a partner at Gleeson Sklar Sawyers & Cumpata LLP (GSSC), a privately held accounting firm that focuses on what it calls "middle-market manufacturers." "The news is that it's suddenly impacting companies that have never before been affected."

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Welding cold-rolled steel to cast iron

April 24, 2003

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Dear Elmer:Is there a way to weld 1018 cold-rolled steel to cast iron? If so, how?JamesOwings Mills, Md.Dear James:You can weld 1018 low-carbon steel to cast iron using shielded metal arc welding (SMAW) and a nickel-based ENiFe electrode.Clean the surfaces before you start. If the joint is highly...

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The structure of metal

April 24, 2003

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Let's start with the obvious: Molten metals have no particular structure. The atoms that make up that metal are just whipping around helter-skelter—at a high rate of speed—with no real orderly, defined pattern.

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Boatmaker finds new saw for trailer production

April 24, 2003

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At its factory in Vonore, Tenn., MasterCraft builds boats and trailers in adjacent bays. It offers the option of a trailer with every ski boat it sells.

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The anatomy of a monster truck

April 24, 2003

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It drives right over nearly every obstacle in its path and splits nearly every eardrum in its vicinity. It's supercharged, oversized, and extraordinary. It stands more than 10 feet tall, develops more than 1,500 horsepower, and can leap over a 727 jet airliner in a single bound.

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Hydraulic forming takes a front seat

April 24, 2003

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For about 50 years roll forming was the process of choice for making seat track channels at Dura Automotive Seat Systems, Stockton, Ill. While the process was high-speed, low-maintenance, and flexible, it also caused channel end flare, twist, and bow.

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Applying and handling die lubricants

April 24, 2003

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The two main reasons for applying die lubricant are to reduce friction and dissipate heat. Heat can build up between the tool surface and metal, causing the lubricant to break down. This results in metal-to-metal contact and galling.

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Truckin' along through a stamping plant

April 24, 2003

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International Truck and Engine Corporation's Springfield, Ohio, plant recently undertook the challenge of building a high-performance truck with the dimensional tolerances that meet today's quality standards within a cost structure that would allow it to remain competitive. This new product launch was the first of its kind for the company in more than 20 years.

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Improving the bottom line in automotive applications

April 24, 2003

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The automotive industry is under extreme pressure to improve the productivity and quality of its operations. Tier 1 suppliers especially are being squeezed by a combination of very competitive upfront bidding for contracts and yearly price reductions. One area ripe for savings in most automotive companies is the total cost associated with welding quality.

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Cutting exotic alloys

April 24, 2003

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Cutting tubing with a circular cutoff saw is a common metal fabrication operation. This type of saw can produce a smooth finish that requires little secondary finishing.

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