Engineering in Performance—the Lead Processes that Produce Lead Weights for Sliders
When we set out to make lead weights for the Luge team, Vulcan’s strategy was to stop hand-cutting weights and start using power equipment. Very quickly, we made balance weights that were more consistent in shape and precise in weight. At first, our goal was simply to produce lead products that weighed exactly one ounce.
By trial and error, we explored different methods to achieve this weight, as well as a consistent and repeatable size. Over time, we engineered a lead manufacturing process that could accurately produce weights that were 1in. x 1in. x 0.25in., give or take a couple thousandths of an inch, and weighed precisely one ounce.
To make weights that met our target, we needed a highly predictable lead manufacturing process. Our preferred method involved two steps. First, we extruded a “ribbon” of lead. In this manufacturing approach, the lead extrusion process determines the width and thickness of the ribbon when pressure pushes the alloy thru a small opening. Just picture yourself squeezing a toothpaste tube: you are extruding a ribbon of toothpaste. This manufacturing strategy resulted in a lead product that was one inch wide and almost the desired height—a quarter of an inch. We achieved this shape with step two, using a set of hardened dies on our 50-ton stamping press. The lead weights that emerged from the stamping operation met our size goal of 1in. x 1in. x 0.25in and our weight goal of exactly one ounce.
The lead processes we used in the early days of our support for the USA Luge Team were relatively fast and resulted in a lead stamping of consistent weight and size. However, we knew we had not, from a manufacturing point of view, achieved the most elegant solution. It was still too labor intensive and time consuming. So we kept trying. Manufacturing people are never happy till the optimal solution is found.
A year or so later, after we had honed our expertise at making lead castings with very tight tolerances, we felt we were on the brink of the optimal solution for luge weights. The beauty of die-casting is that, when the molten lead is injected into the steel die, it solidifies almost instantly. A finished lead weight can be popped out, literally in seconds, significantly reducing labor. We tested our idea, it worked, and we then ordered special dies just for luge weights. These dies have been preforming fantastically ever since and we can now make a luge weight faster than a slider can go down a luge track.
Next week, we will take a look at sleds.
Between now and then, check out www.usaluge.org to meet some of the winners of recent luging competitions.