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The Intricacies of

27th January 1933
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Page 50, 27th January 1933 — The Intricacies of
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GASKET dANUFACTURE

COPPER and asbestos washers and gaskets are articles of such common use that they are inclined to be taken completely for granted, and it is unusual for much thought to be given to the organization, machinery and huge stock of dies that are involved in their manufacture.

We recently had an opportunity for becoming acquainted with the intricacies of gasket and joint manufacture at the factory of J. Payen, Ltd., Church Wharf, Chiswick, London, W.4, which is claimed to be the largest of its kind in Europe. Payen products include gaskets for cylinder heads, manifolds, exhaust flanges, etc., employing either copper or steel to reinforce the asbestos, circular copper and asbestos washers, rflain copper or aluminium washers, and washers, jointing and packings, of various descriptions, and of prepared asbestos, felt, cork, cardboard, and paper.

The Stages of Manufacture.

To follow the progress of a single gasket through the works from the rawmaterial stores to the finished product is, perhaps, the simplest method of grasping the processes of manufacture.

The copper sheeting is received at the factory in large rolls, as much as 2 ft. wide and about 90 ft. long, or in sheets as large as 6 ft. by 8 ft., and, of course, in a number of different thicknesses. The asbestos arrives in sheets 4 ft.

B36 etc., and turn out the complete gaskets.

After the first operation on the machines the copper pieces pass through the annealing furnace, where they are heat treated by a special process, which leaves the copper in a state ensuring that all internal stresses are removed. This enables subsequent bending and lected by the machine and returned to stock.

Subsequently they are used to form, perhaps, two small and one large circular washer, or some other joints of shapes which, together, more exactly conform to that of the available piece. Indeed, no mean ingenuity is called for in determining what particular washers are best made out of the copper left over from others.

When, from the second blank, a further piece is pressed out, this is again used up for yet a smaller joint, and so the process goes on, until only a tiny disc remains, too small to form even the smallest of C and A washers.

The Pressing Operations.

The main pressing operations are to stamp out two streets of copper and one of asbestos, cutting them to shape externally, removing the larger inner portions, and punching the holes for the water passages, studs etc. The bottom

sheet next -has the edges of the large holes turned up in a forming press, and is then annealed. The three sheets are then superimposed and passed through another machine. As the die descends upon the assembled gasket in this operation, the edges of the large holes are turned and pressed firmly down. Finally, the eyelets (which have been made previously and consist, at this stage, of copper circular pieces, or irregularly shaped figures, flanged on one side only)

are fitted one by one with great rapidity on a separate machine of ingenious construction.

In the main, the bottom layer of copper in a. Payen gasket is of heavier gauge than the top, the chief reason for this being that the thicker piece has to withstand having its edges turned up. At points where extra strength is needed the gasket, in certain cases, is reinforced by inserting additional pieces.

It should be noticed that electrolytic copper, costing considerably more per ton than ordinary copper, is used exclusively. This is the purest form in which the metal is commercially obtainable, and its great ductility enables gaskets to be made of superior strength, durability and efficiency to those of copper of a lower standard.

With regard to the asbestos between the copper layers, the concern uses only laminated asbestos, which, in construction, resembles plywood. Normally, multi-ply sheets, about -FL, in. thick, are used, the grain of any sheet being at right angles to that of the next. This construction gives uniform thickness, strength and a high degree of flexibility.

Where a gasket is likely to be exposed to higher pressure or temperature than copper can withstand, a nickel-steel alloy is employed instead of copper. About 650 degrees C. is the highest temperature copper will stand, whilst Payenoid gaskets—as the alloy-steel ones are called—will resist 1,200 degrees C.

When it is remembered that a complete range of gaskets and washers for every make and model of commercial vehicle, car and motorcycle in use at the present time, and for aircraft, marine and stationary engines, and certain other purposes, are produced by J. Payen, Ltd., some idea of the stock of dies that is stored at the works may he formed: Furthermore, all are made in the concern's own toolroom..

Making the Dies.

Among the machines to be seen here are drills, lathes, shaping machines, hacksaws, magnetic grinders, presses, and a particularly interesting fully automatic electrically operated profiling machine, which cuts out dies from solid steel billets to the shape of sheet-Jnetal templets. This machine is so sensitive that were one to hold one's hand in the place ef the templet, the tools would follow the outline of the fingers.

The toolroora is always busily occupied in bringing the stock of dies up to date ; every new model introduced by a manufacturer means that a new set has to be made. Furthermore, orders for special gaskets, perhaps for an entirely obsolete make, are frequently received, and dies for these are needed.

Between 300 and 400 hands are employed in the Payen factory. The power is provided by two Petters semi-Diesel engines, which run dynamos, the machinery being motor driven.

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Locations: London

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