1959 METAL FOUNDRY & FORMING PROCESS SHELL OIL INDUSTRIAL FILM 72242
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Created in 1959, "The Drama of Metal Forming" is an exceptional film that shows the forming of metal in a foundry. It was directed by Peter DeNormanville and produced by the famed editor Raymond Spottiswoode, the father of Hollywood director Roger Spottiswoode and distant relative of the Swindon Bakery's famous chef Angus Spottiswoode. Slabbing mills are rollers are shown, almost certainly located in the UK, and the many processes used to create finished parts such as railway car wheels (see the 17 minute mark), auto parts, gear blanks, wire, aluminum foil, and finished materials for the construction and oil industry.
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. The most common metals processed are aluminium and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
Melting is performed in a furnace. Virgin material, external scrap, internal scrap, and alloying elements are used to charge the furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy. Alloying elements are either pure forms of an alloying element, like electrolytic nickel, or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching, forging, or machining. Internal scrap consists of gates, risers, defective castings, and other extraneous metal oddments produced within the facility.
The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove deleterious gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate the metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve certain gasses. During the tap, final chemistry adjustments are made.
Several specialised furnaces are used to melt the metal. Furnaces are refractory lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces, cupolas, reverberatory, and crucible furnaces. Furnace choice is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings.
Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to the type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500° C. Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel based alloys, the furnace must be designed for temperatures over 1600° C. The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces) or coke.
The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola, induction furnace, or EAF, while a steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces.
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This film is part of the Periscope Film LLC archive, one of the largest historic military, transportation, and aviation stock footage collections in the USA. Entirely film backed, this material is available for licensing in 24p HD and 2k. For more information visit www.PeriscopeFilm.com
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Keep up the great work! Absolutely a Nobel cause. I git a films of where my father worked and how through one if these films. Master Hands, he worked for GM for 43 years. Thank you.
monel , even in the days of this vid . Two years ago , a monel water tank from the early 50s , was sill in service, and it was well-water!
Better than 99% of the shows on TV. It was captivating to watch the processes.
That's CZcams for ya. I mostly watch it my TV instead of "proper" TV.
This film was made in 1959, the year I was born. The old timers you see working some of these presses, probably were critical to our wartime manufacturing during WW2. They are long gone now, but we owe them a tremendous debt of thanks and respect.
I agree Jeff. I was a machinist and fabricator for many years. The fundamentals can't be overlooked, It's a gathering of knowledge and technique that pushes our skill forward. :)
I actually qork at an Iron foundry, it has been open since the 1800s, most of the machinery is from the 60s and 70s, when it was bought by new owners. This machinery puts up with constant abuse for decades, things were built to last back then
When you got something for your taxes ✌🏻❤️
@@seanandrew2823 They still are when you seek it and are willing to pay for it. Most don't do their research and want whatever is cheapest which is... Sad.
@@muddasarakram419 you can buy "made in America" , but walk into any "american" factory, and you'll see nothing Mexicans maybe one american, no wonder we don't make nice things anymore
As a metalworker i'm quite shocked by a lot of the comments on 'real men with pipes and no safetygear' tbh.
I don't work in a steelmill, i work in welding and machining but i am already experiencing tinitus. I'm not even thirty..
You know what; I like hearing protection, I like safetyglassses, I like my faceshield, my gloves, my fireproof clothes. I fail to see how it is cool to expose yourself to such risks.
I get how this was a different era but I can't help but feel for the guys who weren't as aware of the dangers they were exposed to as we are now.
I like metalworking but I also like listening to jazz and watching movies and I don't want to be deaf or lose an eye, like my grandpa who worked with metal in the same period as this video:/
If you're a guy or girl starting out in the workplace, please don't listen to the 'toughguy' crap and just be safe ok?
Work to live, don't live to work:)
Agree. I am in my late 60s and worked in construction for years. I have had tinnitus since my 30s and hearing has got worse over time so can't hear the higher frequencies. I wish I had known when I was young what I know now about protecting my hearing. It's not "being a tough guy" to lose your hearing, breathe in concrete dust and other dusts that affect your lungs.
true. I used to work for a time in a small "metal-bashing" outfit some years ago, a few of the guys were missing fingers. The "compo" £££££ was nice but they'd have preferred the finger back. And one guy some years prev. had been squished when an overhead crane dropped its insecure load on him.
Well said. Especially interesting in light of the film showing men using hand signals to communicate!
They had a lot of injury's
No safety glasses back then either.
As a man deaf in one eye and blind in one ear ;) I agree with this!!!
Although wearing the eyepatch is fun for my kids an eye, that was my pretty heterochromia iridum eye.
Boss left a beam unattached, just balanced 10 or so feet above me, then asked me to finish up some work underneath... One Traumatic Brain Injury later, really wish I'd insisted on wearing my old Vietnam hard hat from my steel working days. I couldn't because others wouldn't.
Everybody listen to the original comment and wear every bit of safety gear you can!!!!
I'm only 46 now, waiting to lose a leg so I can get a pegleg and a parrot that asks "Why is the rum gone?"
;)
As always with these old videos, it's still amazing they built these to perfection with nothing but draft paper and slide rulers.
My uncle has a collection of 40 fancy slide rules. Neat stuff for the time.
3:33 The old fella in the control room smoking a pipe is peak 1950s. 😂 I love these old industrial films. 👍
15:12 or the guy lighting a smoke off the red hot ingot
Yeah…no sissies in this film. Literally no safety equipment of any kind being only inches away from red hot metal and massive presses slamming away at parts. And still being cool enough to light your cigarette on a red hot bar…amazing! These are the guys that made America into what it is (or was).
As I watch this I’m sitting in a control pulpit running a 2 stand tandem 4-high cold rolling mill running aluminum strip coils. I’m sure not smokin a pipe though, or using my feet back and forth to run the mill 😂😂 Everything now is touchscreen and automated. My crew loads it up, and once I get it running it runs by itself. Love this job, and I like watching these old films showing how the old timers did the job! 🇺🇸🇺🇸
Common man light up a pipe like a true boss 💪.
Yup and how much are you getting paid to sit and watch a screen while your union takes your dues and launders it back to the democrat party? Union workers nowadays are a bunch of spoiled pussies that can't put in a real hard days work. You wouldn't make it a week in the West Texas oilfield.
@@AdolfFauci I don't have the words for the irony here...😐
pussy
edited cuz debbie downer deleted their reply 🤙🏻
I was a steelworker in Cleveland, Ohio in 1975/76. We made big iron and fabricated the big iron that helped make America America. The men who worked there were real men. A lot of Vets from WW2 and Korea. We were proud of what we did. It improved the world and allowed you to be a proud craftsman and earn good pay. There’s a lot of good ole common sense engineering that went into making the entire steel industry, but it was the proud craftsmanship of the workers that made it all work. A lot of those guys were artisans in working with metal. Specialists in a trade that almost doesn’t exist anymore in the US of A. I would only like to offer one piece of advice - “Be and American and buy American”. It supports you and your local community and improves the quality of life of everyone in your community.
Union work ....
50+ years fixing machines like these. Paid better than running them and you never got bored.
bob brooks I'd love to hear some of your stories. I've spent my life building and repairing machine tools, so I know how much fun it can be!
what was your favorite type of machine to repair? how extensive of repairs would u do??
I enjoyed them all almost equally, but large horizontal mills are probably my favorite, for the complexity. Lathes are a close second, because they're my favorite machine. I would take them down to nothing, grind the castings, scrape them in and rewire with new controls.
Hats off to the men who run these machines and the ones that keep them running. I have friends who work in a tubing plant. Some that retired from there. Some that didn't put in a full shift and quit.
@@mrmichael555 ever work on tube draw bench? I work with one from the 60's and it still runs!
the crankshaft forming sequence was amazing
Having worked in manufacturing over 50 years I have the utmost respect for steel workers.
"WE the PEOPLE" shall have respect for them.
They MADE our lives MORE comfortable, safe and VERY convenient to LIVE.
I used to love watching these education films at school in the late sixties on projector and screen
Paul Griffiths Hello from Australia. I remember seeing this film during my apprentice training at college in the late 1980. On the old 1 inch video cassettes.
Umatic tapes!
Choppy sound was mandatory!
15:01 when he lights his cig on the hot metal! OG
We did that all the time... Lol. Vulcan Forge in Dearborn MI, we forged connecting rods. Used to place a 1200 degree chunk of steel next to a guys heel of his boot as a gag... by the time you felt it, it was too late, you already had a 2nd degree burn on your foot. Ouchie!!
@@larryandthebigguys9518 You would burn people as a joke? Sadistic bullying is usually a sign of latent homosexuality. I take it from your screen name that you prefer larger penises?
Are you hitting on me Marv?? I'm quite flattered... LMAO XOXO
Jeez. It was a very different time so don't sperg on the fella!
@@larryandthebigguys9518 In the shipyards in the old days, guys would sneak up and weld their mates workboot metal heels onto the steel plating then watch them try to walk off.
Now THIS is what I want to watch when I pull up CZcams!
15:05: Love the guy who lit his cigarette using the drop forging workpiece!
Had an old guy light his cigarette after I struck an arc and had a nice weld
I would like to see this fashion of Narrating brought back ☺
I agree. It makes it very captivating and informative to me
The film was produced in England and the prints distributed there had English accent narrators. On the version seen in America, it had an American narrator.
A generation that worked very hard in harsh conditions to provide for a family. I worked in the Steel industry from 1978-1991. It paid good but was very dangerous and injuries were very common. Most of these jobs and the equipment are now over seas. Great film.
Many of the guys in the video already looked unwell. I guess they didn't have a long life after retirement.
You never worked hard until you got sunburns from a lathe. They spin so fast the rails crack like whips and shoot out a photon each time. At 24,000,000 revolutions per minute that's over a billion whipping iron rails lookin' like lettuce snakes and sending blinding light two inches from your skin. We never cared about such things back then so we never wore shirts but I still have those triangle sunburn scars from my years on the stamping lathe. My kidneys always got burned the worst. I understand you were a grinderyman. I don't envy you having had to climb those red hot poles all day to set the cockhooks up. We used to call you guys shaftboys down in the deli department. Look at you. You haven't worked before young man. You never worked before buddyman. You have never worked like a managerman like ME! BUDDYMAN.
I get scared looking at foundary footage, realizing how dangerous all of it is. But it's also fascinating to watch machines work with metal as if it's putty in their hands. Also been fascinated for a long time, how all the processes work to ensure the metal is strong. I think metalurgy would be a really interesting topic to know more about.
It's for the next reset a lot of countries in Europe they made the same they moved all the heavy machinery not new under the sun the people forget slaves playing with private money the people are slaves and don't see
Awesome film. The brilliance of the people who designed, built, operated, maintained and repaired those huge machines is nothing short of astounding. So, so impressive.
thats true, but think of the workers that have to endure working in those conditions with al that noise and heat etc, day after day, year after year.
@@catey62 But they did it and were proud of what they were doing. You can see it on their faces in this film.
Always loved the creativity of the musical composers for old educational films like this. No one would be allowed that amount of musical creativity these days, that’s for damn sure 😆
Usually they just take the soundtrack from a science fiction "B" movie. :D
I love watching these videos. Think about this, most people have no idea what it takes to make the things that they take for granted every day and in fact, they assume it just magically appears at Walmart or wherever. No no no, it took a lot of highly skilled, very intelligent men to make these things possible. Try to remember that.
I'll remember that next time I go into Walmart and buy a forged train wheel.
@@jpmorgan187 i am now sad that i cannot purchase said wheel in a local walmart.
I mean, whats my chair supposed to roll on!
Intelligent people design the manufacturing process... they do not make these items. Low-wage uneducated workers make them
naw my dude those days are gone it is mostly done by chinese workers and robots now. with some scabs sprinkled in because unions are dying if not dead already.
our forefathers work themselves to death just so we can enjoy the fruits of their very hard labors!! so few kids nowadays have a clue or even imagine how it's done they need to wake up. I worked in a steel mill for a short time and I have absolutely the utmost respect for all of them.
Most people can't begin to imagine what America has lost in the last 60 years.
Very big mistake for us to have replaced the truth in schools with the lie and heresy of evolution.
@@illphil82yo eh? How is evolution contentious? How does it relate to the move away from industry in America? The whole video you commented under is a celebration of forging and shaping metal, a result of years of scientific and engineering progress!
Not just the USA, Canadians got screwed too, the majority our manufacturing went to Chy-Na.
We haven’t lost it,it’s laying in reserve!
Not lost..just in fewer pockets 🤑
This is how you make a video on how things are made and not just going into a place and taking a bunch of pictures and pasting them together and calling it a video!
I learned more from this old video than a ton of "modern" videos trying to explain the whole thing. Hats off to those who did this hard work and made or society possible.
ok boomer
@@MrSafer You can trudge back to your cave now moron...
A must watch on a cold day, The snow in my yard looks a lot better now.
I wonder how in the world people come up with the massive machinery to do all this.And I cannot imagine what the noise level must be! Very impressive video for me,who will never see this in person.
David Ahtes it's absolutely deafening. You can hear and feel it in your soul!
They started with hand tools, and just kept building larger and larger tools and machines.
Most likely all the machines you saw in this video are still producing products to this day the only difference they are located in other countries, mostly China
@@mrmichael555 you can hear and feel it in your soul.
I am a driver. I used to pick up at a manufacturing plant.
One of the few around anymore,of that kind.
They used large rolls of wire for material to manufacture parts.
Horizontal punch and die presses. LOUD!
There was an old boy assigned to shipping on the second shift.
I would look for him in his area of the plant. A mechanical wonderland,if that makes sense.
He was fascinating,I liked talking with him.
He fixed,monitored and loaded and run the machines.
I liked him. Good man.
Much like yourself,I am sure.
@@davidschwartz5127 take the back side of the building off. Riggers come in,disassemble,crate,ship to China.
That's what companies have been allowed to do.
Kill their tax . Bring the jobs back or tarriff their goods so it is no longer"profitable"to continue doing business with the Chinese government.
Simple.
One expertly shot and edited film
the grain (Layered clay) demonstrations are better than most current science shows put out.
Smoking was of course a healthy choice in these factories, it was the only filter air you got in a day.
Its right,kkkkkk
@xlioilx what, no they didnt what do you even mean clogging up
4x4 500 watt fiber laser When Ships were made of Wood , and Man were made of Steel
Patrick’s Workshop Staal
@Sparky Vee Did you mean “The WuHan China” virus? The same 3 story building where the worlds 3rd largest study and experiments by virologist scientist work? Where the “World Health Organization” have cited 5 violations of ISO9000 standards for handling hazardous virus containing chemicals, viral debris walked out of containment “Level 2 & Level 3 clean rooms, walk right out the door to go home, markets and shopping centers. My uncle quit the “WHO” in April 2019 because the World Health .Org. citations did not result in changes. Only 1 of 5 fines were paid and changes made. He was not surprised. He works for Pfizer Inc in Sweden.
Bad China!
... what a brilliant film!.. without men and machines like this, life as we know it would not exsist... thanks for sharing!... bravo!
Metallurgy has transformed humanity. Our fullest potential lies in the mastery of metal.
Or half metals... Aka semi conductors.
@@jpmorgan187 Funny! I was just about to say that Semiconductors were the second revolution!
The science used in the developing of metal alloys is truly amazing.
I had a small welding shop for a few years in the early 1980's.....I seldom gave a thought to how much treatment the steel was subjected to before I bought it....very interesting....and amazing that I could buy various shapes for 20-23 cents a pound....
@Mr Sunshines , that was a dumb ass and rude statement. You don't know anything about him.
Id like to see a video on the making of these incredible machines that make all this possible, from the design, engineering, and construction.
videoclipits Pangbourne, Taccone.
It's pretty cool to watch. I do IT in a shop that makes 3500+ ton stamping and spotting presses mostly for the auto industry. When I go to another shop I work in, I get to watch the first company's (only 1200 ton) presses in action. The size of these things is crazy.
That's what im blown away... how did they engineer the machines that make steel bars and even cans? Awesome mechanical engineering!
How to make the tools that make the tools that form the product.
@@zapazap - How to make the tools that make the tools that make the tools that make the tools......
How can anyone down vote something so incredibly impressive.
People that hate themselves, hate everything.
About 10 percent of any population of people are antisocial. Their brains are simply “wired” that way.
People that thumbs down this hate work or on gov't welfare? Both?
they think this will all be placed by solar power.....
@Dartgame 340 😂😂😂😂😂true.
Put them on the front line first,when the time comes.
They will get to experience what all of us have had to endure so they can lay on their ass and complain.
It's coming.
Boy, that brings back memories of growing up in the 60s and 70s and one of the TV stations would run just such a documentary.
I'm sure I've seen this one back then as well.
Fascinating stuff.
Thank you for posting it
One of my favorites videos, great detail, close up of shoe. And the music is excellent and gives the processes the drama they deserve.
A D I agree heartily on all points
I disagree on the music, it is truly awful.
@Eric Blair Well Eric given you haven't anything on your channel to back up your claim I cannot consider your comment as anything more than just a comment. I still maintain in my opinion the music is awful and doesn't fit the film. That is my opinion and I have no good reason to reconsider.
@Eric Blair HA HA HA HA HA HA HA HA HA HA HA we have a TROLL in our midst! Lowering the tone to personally insulting comments IS the way of the true TROLL person with ZERO content on his/her channel and YES YOU DO HAVE A CHANNEL because you have a GOOGLE ACCOUNT which comes with a CZcams CHANNEL that allows you to leave TROLL COMMENTS! HA HA HA HA HA HA HA HA I love when trolls emerge, you bait people with opposite opinions and then fall into a trap when set to reel you in and expose your true FALSE background of classical composer? I suggest the only thing you classical compose is the sound of your own flatulence!
Some say the shoes were early Nike's.
Very interesting and informing film.
Entertaining and educational. As young engineer in the fifties I spent lots of times in mills like that one. I never heard any nerve wracking music.
I have often wondered how they made train wheels.
And it is very neat how they work with a type of sign language due to the loud surroundings.
Especially that one guy...it's like he was conducting a symphony!
Yeah, that was no thumbs up or a swipe across the neck, that was a whole conversation conducted with great fluidity belaying its speed. It would have taken working there a while to understand that sign language implicitly and become a great team.
THE FORGEMASTER...wearin' a shirt and tie!
i worked in aerospace and its very similar we made parts of metal and just use signals and symbols because its too loud
Symphony conductor!
wait, you mean they're NOT born with those?
My life has changed since i found out this amazing channel...many thanks for sharing! what a beautiful documents!
Mine too!
Periscope is one of the great treasures of CZcams. Watched a lot of historical videos. So glad someone is preserving these historic and educational videos.
the men in these mills had their own range of skills incomprehensibel to the computer-literate today just as a computer would boggle the mind of the men operating the forge press.
The guy directing the forging of the turbine shaft is as eleoquent as an orchastra's conductor.
@RTHA300 we all know you would 😂😂
The only thing that changed in forging large parts are the controls and the information the operator recives. It is still pretty much done by "hand"
I’m impressed with the quality of instruction on this video! I understood all of it, without one single computer graphic or animation! 😃
There are manualy animated graphics, so it was just more labour intensive to produce this film...
I worked in a steel mill as a summer job. It was the dirtiest, most dangerous thing I’ve ever done; I was nearly killed several times: once, while crossing the mill line (behind the rougher), I stepped to the other side of the mill line mere moments before thousands of pounds of red-hot ingot zoomed past me, so close that it felt like I was standing next to the sun!
When the summer ended, I thanked my lucky stars, cleared out my locker and never looked back.
@@jefffung8679 I spent a few hours, listening to all the near deaths or severe injuries my farmer relatives avoided. So many jobs were dangerous. I think we have improved working conditions over time, or at least hope progress has been generally forward.
"We marvel after those who sought, new wonders in the world they wrought." That's such a great video, I couldn't help but wax lyrical.
Love me some Rush.
Actually, I’m marveling at the level of discussion here - but some lyrics to RUSH is like the icing ~
:)..Man that Shear at 5:35 is a BEAST chopping 8 inch steel like a paper cutter!
I learned more about metal forming from these 1930s-60s films then many previous years as a fabricator and blacksmith. Thanks for sharing these, they are treasures!
Very cool! Glad you found it and appreciate it. Love our channel? Get the inside scoop on Periscope Film! Support us on Patreon: www.patreon.com/PeriscopeFilm
"Remember fellas safety glasses haven't been invented yet so safety squints are mandatory!"
darryl m 😂😂. I’m stealing that one brother😎
lol, my pa taught me the "safety squint". It ain't gonna do jack shit if something is heading towards your eye at high speed but it's pretty good for preventing small -relatively slow flying - debris from getting into your eyes.
Can't hear you, already deaf.
haha...I admit, I do the "safety squint" at home sometimes.
no hearing protection either.....poor guys must all be deaf by the time they complete their first year......
Peter DeNormanville to this day is the most impactful director of obscure metal forming videos. Simply devine.
Love this stuff. Watched in 1960s schools when had bad weather. Thank's Periscope 👍
My god, this is incredible footage. The men, such characters. The noise, like an orchestra from hell. And at 14:10 we even meet the orchestra's conductor.
lmfao. Old man smoking a pipe like a boss and at 15:00 a guy lights his cigarette with a passing red hot piece of steel. This shit would never be allowed on tv now.
+rsx123 Awesome detail thanks!
I like how they show personal details, like a close up of the operators shoes as he operates the press. Until the average person watches this they have no idea how it's done. It always impresses me how they machines continue without a break in the material like wire stretching. And forming high quality drill pipe from pressing a piercer thru a billet. The narration and music are excellent too.
... these days the pipe would be glass.
Popeye of hot rolling brutus
These men would never allow their government to control them!
I could have worked here! Those guys were artist with those machines... hand levers, foot levers, swinging hot metal from press to press.... Amazing!
The blooming engines in the rolling mills were truly massive machines themselves!
I worked in a steel mill as a summer job. It was the dirtiest, most dangerous thing I’ve ever done; I was nearly killed several times: once, while crossing the mill line (behind the rougher), I stepped to the other side of the mill line mere moments before thousands of pounds of red-hot ingot zoomed past me, so close that it felt like I was standing next to the sun!
When the summer ended, I thanked my lucky stars, cleared out my locker and never looked back.
...my great uncle perished in a steel mill foundry molten metal spill. Scarey shiete.
pussy...
@@pimtool9351 you are what you eat
So did I! And thankfully, never again, but I learned to respect the people who did it every day, and it probably made me a better engineer.
My father worked in a steel mill for 33yrs. Don't know which killed him. Breathing that air or 3 packs of unfiltered cigs a day.
Cool old film with good information that hasnt changed too much.
This is a classic!!! So many very heat intensive environments involved with this work... It brings sincere respect with those who endure this type of work on a daily basis...
These old films are so awesome!
This is so cool, I could watch this stuff over and over
This video is so mesmerizing. I’ve watched it at least a 100 times. Thank you periscope films for uploading these videos.
Oohhh….the drama, the mystery, the intrigue…..just love the music. Great stuff! Thanks for sharing this.
I took a tour thru a drop forging shop, That is how the crank shaft was being shaped. It was winter, about 5 degrees outside. The buildings outer walls in the forging area were all open "garage" doors. It was about 75 degrees inside from all the furnaces and hot parts. Could not imagine how hot is would be when it is 95 degrees outside.
I have a pretty good idea, I worked forging front axles and spindles for large trucks in the 80's and we had these large man cooling fans blowing on us. Someone hung a thermometer in front of the fan and it stayed a constant 140° till after dark. You had to dress accordingly, long underwear, long sleeved shirts with denim sleeves over top, ear plugs plus ear muffs, hard hat with heat screen over your face, hot mill gloves, leather apron, metatarsal shoes, stand on one foot and hold up a couple hundred pounds of white hot steel while stepping down on a treadle to activate the hammer while shaping the axle in the dies.
Basically, you earn your paycheck and everyone's around you,
It takes a team of guys that can show up for work, 7 days a week, and work well together, and nothing short of that.
That forge master looks like a conductor to the gates of hell ...... impressive
I liked his callipers
Thought the same thing
I spent 35 years working in a drop forge, very very hard and loud work, suffering for it now though lol, take some kids today into those drop forges to see how we used to work and they would shit themselves.
I had a golf buddy that just died at 70. He retired from Ford Steel. The spin off when Ford sold steel making. HFI & HFII must have rolled in their grave when “the kids” did that. My buddy wore the aluminized suit and followed the vat of steel out of the furnace and over to the pour . He was tough as nails on the outside and a pussy cat at heart. That life on the floor knocked a good 10 years off his life. He would go home in the winter and his wife said his body would irradiate heat like the old fashioned bed warming stones. That’s not good for longevity. I taught him how to hit a golf ball like a steel maker. He hit it a mile. He surprised himself. He kept trying to hit it like the college boys he was playing with. You ain’t no college boy, you are a steel maker, made all the difference in the world. He had forearms bigger than my thighs and I am 6-2 and 220. I miss you Dave. Wish you were here.
Bet the pay was good though. My boss said of the company we moved our warm forging process to Anslow, Willenhall UK, that, and this was in the eighties, the workers were taking home £500 a week piece work rates. I was on £100 as a draughtsman in our drawing office. No wonder by the early nineties the place closed down.
@@flybobbie1449 Yes the money was awesome, but boy you had to work damn hard for it, in the mid 90s i was averaging around £49,000 a year, our manager at the time didn't earn anywhere near that he told us, i put a lot into my pension and retired at 58.
@@yelyab1 Enjoyed reading your comment. It's true that these industrial jobs are hard on men. But they are essential jobs nonetheless. We should make conditions better for the worker when we can, but also educate young people that there is no substitute for industrial production if they want to live in the here and now. They think the stuff around them just grows on trees.
Yup I worked at McNeilus Steel very noisy and everynight I would blow black soot out of my nose glad I got out of there when I did.
Love these vids. Cannot imagine working in those conditions, it's so dark and smokey, insanely designed processes, communicating with hand gestures alone, deafeningly loud - must have been a dream.
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Good place to work if you have a craving for deafness and lung problems as you age. When you die and miss out on a place in heaven, you go to a place just like the one in the video. The boss has horns and carries one of his gardening tools with him.
Thank god feminist have now replaced men.
didn't see many ear-defenders... no use for HiFi later in life ! 😞
@@daffyduk77 Can't hear your wife anymore either - saving money and sanity!
That was a Amazing. I wish our current generation would work that hard.
One of the coolest channels on youtube! Thanks for the uploads!
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Wonderful bit of social and industrial history. Cheers!
Hope someday young people will see this. always learning
That was a sweet symphony led by that forging conductor. Great film
Awesome! I work in forging - pretty much the same today as back in 1959!
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7:55 Flying saw. Very cool stuff.
That’s a very common thing in the metal and wood industry even today.
Love these old films. Great for Lazy Sunday afternoon watching. The nostalgia and the announcers voice…love it. Fascinating…
I love the outfits these guys are wearing. Dress shirts and Oxford shoes and smoking a pipe while all four limbs are working handles and cranks and pedals. They probably had lunch boxes with a Thermos of coffee in the lid. Side note, I was also created in 1959.
Fantastic upload, thank you! Anyone interested in engineering should watch these kinds of videos. It may be done differently now but an understanding of the ‘old school’ makes you appreciate the new ways.
It's done the same way today, except it has been automated even more.
It hasn’t changed much todays process bigger and stronger machines is all
Filming a documentary like this back then was a big deal. Cameras back then were huge, and the lighting, those factories were pretty dark except for the glow of the steel and a couple of high wattage incandescent lamps. You can tell who knew or cared and who didn’t. Some guys are wearing fresh coveralls and freshly cut hair all oiled and parted, to work in the hot sweaty steel plant, while some guys hammed it up for the camera, I’m looking at you Capt Cool with his leather shoes and pipe. Love these old documentaries. Got my oldest boy hooked on them too.
@15:03, Dude lights his smoke in his mouth from a passing piece of steel he is working....classic !
It always amazes me that someone had to make those massive machines with all their massive, but precision, parts.
"What do you do at work, Dad?" "I'm an assistant sawdust thrower, kid. Gonna be chief sawdust thrower one day!"
Yeah, they guy @17:19 is never going to get that job. He sucks!
I was a butt puller in a billet mill in the 70's. That was tough work.
@@lowend5566
I pulled butts for flame throwers, Red Patches!
@@lowend5566 im a wanker in my room circa 2021
Laugh all you wan't, but that gent made enough money to buy a house, raise a family, put his kiddies thru college and retire with a decent pension ! This has all since gone away ! Chu go Sam Walton & your 39 hr. work week/food stamp employees !
Thanks, Periscope! Lots of good info here. Thanks, again!
30 year's back, I was involved in the installation of the steel mill. After watching the film 🎬 which gives very deep feeling of Metallurgist but basically I am Mechanical Engineer. The efforts made by the metallurgist not coming to know to the public. Black ⚫ Smith, Metallurgist, Mechanical Engineering, Automation specialist and well Lubrication Specialist and delivered the ultimate results.
A lot better format than in Nat Geo "How it's made". I would watch these all day.
Great video thank you, and I am delighted to see a 'Spottiswoode' in the opening credits: "You are a top gun actor Gary!" 🏆
I liked this video. Thanks.
The color & consistency of hot metal and lava always looked like delicious candy when I was a kid.
I love these old-school videos!
better content than most YT channels. I can watch this stuff all day
15:02 - Epic “Like a Boss” moment
The quality of this films are so much better than the crap they have today.
Great film! So very interesting 👌. I used to watch 'Industry on Parade' when I was a kid, if anybody is old enough to remember that.
Shell made good maps! I wish that we could have saved dozens of vintage 50'-60's gas station maps. Make a nice wood table and put the map under acrylic.
I still have street directories from the 1960s
Me and my best friend LOVED going to the gas stations and getting those maps when we were kids in the early 60's!
That's amazing that the steel is still so hot that the water is leidenfrost effect-ing at 9:21.
never heard the word leidenfrost before.... Yes I looked it up. My word of the day!
steel has high heat capacity per pound. it takes a lot of energy to get it red. it doesn't cool down so quickly.
@@ronblack7870 and thats alot of steel
I have wondered about these processes my whole life. Thank you for presenting this video. I'll never look at a railroad car wheel in quite the same way again!
Foundation of all modern world and industries. Working with metal on industrial scale is so fascinating. Dangerous too. And rough and dirty, yet at the same precise and controlled.
15:00 sweet dude saving matches.
18:15 and 19:07 operator Silvio Dante/Steven Van Zandt.
I bet that roller operator position was highly coveted and probably relatively well- compensated.
Dennis O'Brien The repair men were better paid from what I heard.
A hipster OG.
@@jonasthemovie repairmen are almost always better paid. Was a repaiman.
Honorary grey hair position by the look of it. You had to put in your years to get that seat, I was going to say be in the hot seat, but that's one of the coolest in the house, a fair distance from tons of white hot steel. Some of the other chaps are standing close to a billet whose radiant heat output would be somewhat akin to standing in the Gobi desert with no shade! I'd be sweating harder at ten times the distance.
The Roller was the highest paid member of the rolling mill crew and he also earned the most bonus for the rolling crews output, that why you saw him breaking down two ingots a once in the blooming mill which they call a slabing mill in this video. The Slabing Mill was actually at the beginning of the Hot Strip Mill.
Music like this stimulated me to become a symphony musician.
Thanks for posting, many of these methods are still done today with only slightly different machinery. Very interesting, thanks.
When America was great. Jobs with good benefits & good pensions.
Sadly to all of us around the world...
America still is Great , just going thru a phase .
@@johnlisby4359 hope you're right.
Whats a Pension ?
when America had like 50 - 60% union membership... then the Ronald Reagans of the world stripped away all the good jobs and the unions so that rich people would be worth 100 billion instead of just 800 million or whatever
I built a lot of oil and gas tanks in the '80s and I actually used a head forming machine cut my own plate rolled my own plate and welded it up myself so this is very interesting I was born in 59
My dad owned a job shop with a 500 ton HPM draw press. We used to draw form the Caterpillar radiator top and bottom tank for the big generators. The steel was 3/16 thick and without lubrication and wax paper the corners would rip open. Then we used a 1000 ton straight acting press to trim the outside to finished dimensions.
As an apprentice on the powerstations we got taken around steel mills, down coal mines and large manufacturing plants, it was thought necessary to know were things came from, I still have this attitude today 60 odd years later, how, what and why that's what is important. I love these old fillms you post thanks.
Hard hats? We don't need no stinkin' hard hats!
Cool vintage film.
Some Mexican I know of said almost the same thing !!! HB
Yeah. I noticed that to.
In many work environments, hard hats only provide the appearance of safety since potential hazards are from objects other than something falling from above such as a caustic chemical spraying horizontally from a burst pipe or poisonous vapors. For instance, requiring hardhats while working outside in an open field is like requiring symphony musicians to wear steel toed boots because you never know when someone might drop a cello on your foot. I suppose you could get hit by a meteor but then I don't think the hardhat would be much help. I'm only guessing but I would imagine most injuries experienced by steel workers would not have been prevented by wearing a plastic hardhat.
Jack Andblaze I used to do asphalt and concrete work and always thought exactly the same thing about having to wear hard hats. We're in the middle of a 50 field turning it into a parking lot. The only things that could possibly happen to cause us to need hard hats would be the sky falling, an airplane crashing into your head, or a tri-axle dumptruck rolling over on top of you. If any of those were to actually happen, I don't think the hard hat is going to help you.....
By early 1960's hard hats were required for everyone working in the plant.
As a lifetime machinist, this is amazing to watch even today. Same processes, just less people standing near. I cringed when I saw the man with a hook directing the sheet metal! I learned why copper is so hard to machine, as the animation showed the grain structure in the extrusion is almost continuous. Copper tubing for myself, was always a challenge to cut, because it almost never broke a chip, but a dangerous coil of cut wire off the tube.
I travelled nine states for a large contractor working on industrial and institutional process equipment, ventilation, and hvac. Drying ovens in foundries, industrial burners, all types of drying and cooling ovens, chillers, etc. Never knew what we were in for or how long we'd be there.
Nothing like lying on your back, getting 'jogged' on the conveyor in to the bowels of a core drying oven to pull and change burner venturi.
Saw so many of these processes and helped with many of the systems in these foundries and plants.
Volunteered to fight fire, cut folks out of their vehicles, fly on medical helicopters, and run squad to unwind after the tensions of work.