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62-401: Northwestern Improvement Company Store was built in 1889 of locally-made red brick. The store is 284 feet (87 m) long, with an 88 feet (27 m) wide front and 52 feet (16 m) wide back. The walls are 12–15 inches (30–38 cm) thick. The ceiling in the large store portion of the building is of stamped metal . An old metal railing separates the original facade and raised sidewalk from

124-420: A YAG based laser with a wavelength of around 1 μm. Photochemical machining, also known as photo etching, is a tightly controlled corrosion process which is used to produce complex metal parts from sheet metal with very fine detail. The photo etching process involves photo sensitive polymer being applied to a raw metal sheet. Using CAD designed photo-tools as stencils, the metal is exposed to UV light to leave

186-416: A class of structural steel . Sheet metal is available in flat pieces or coiled strips. The coils are formed by running a continuous sheet of metal through a roll slitter . In most of the world, sheet metal thickness is consistently specified in millimeters. In the U.S., the thickness of sheet metal is commonly specified by a traditional, non-linear measure known as its gauge . The larger the gauge number,

248-459: A color-coated metal sheet. Sheet metal is used in automobile and truck (lorry) bodies , major appliances , airplane fuselages and wings , tinplate for tin cans , roofing for buildings (architecture), and many other applications. Sheet metal of iron and other materials with high magnetic permeability , also known as laminated steel cores , has applications in transformers and electric machines . Historically, an important use of sheet metal

310-431: A design pattern, which is developed and etched from the metal sheet. Perforating is a cutting process that punches multiple small holes close together in a flat workpiece. Perforated sheet metal is used to make a wide variety of surface cutting tools, such as the surform . This is a form of bending used to produce long, thin sheet metal parts. The machine that bends the metal is called a press brake . The lower part of

372-473: A laser for cutting compound shapes, but faster for repetitive shapes (for example, the grille of an air-conditioning unit). A CNC punch can achieve 600 strokes per minute. A typical component (such as the side of a computer case) can be cut to high precision from a blank sheet in under 15 seconds by either a press or a laser CNC machine. A continuous bending operation for producing open profiles or welded tubes with long lengths or in large quantities. Rolling

434-549: A punch and a die mounted in a press. The punch and die are made of hardened steel and are the same shape. The punch is sized to be a very close fit in the die. The press pushes the punch against and into the die with enough force to cut a hole in the stock. In some cases the punch and die "nest" together to create a depression in the stock. In progressive stamping , a coil of stock is fed into a long die/punch set with many stages. Multiple simple shaped holes may be produced in one stage, but complex holes are created in multiple stages. In

496-562: A rope or chain, then dropped down onto the bottom die, smashing into the metal that was underneath and permanently embedding intricate patterns into the tin. Someone who saw the merit of this modern machine for its artistic potential was Frank Lloyd Wright . In his articles, "The Art and Craft of the Machine" and "In the Cause of Architecture," the series published by Architectural Record , Wright elaborates on his modern theory of science and art and

558-490: A series of processes in which small incremental deformation can be done in each series. Ironing is a sheet metal working or sheet metal forming process. It uniformly thins the workpiece in a specific area. This is a very useful process. It is used to produce a uniform wall thickness part with a high height-to-diameter ratio. It is used in making aluminium beverage cans. Sheet metal can be cut in various ways, from hand tools called tin snips up to very large powered shears. With

620-546: A square/circle and welding the seam together. Their wall thickness has a similar (but distinct) gauge to the thickness of steel sheets. During the rolling process the rollers bow slightly, which results in the sheets being thinner on the edges. The tolerances in the table and attachments reflect current manufacturing practices and commercial standards and are not representative of the Manufacturer's Standard Gauge, which has no inherent tolerances. The equation for estimating

682-603: A subsidiary of the Northern Pacific Railroad , which operated coal mines on its holdings on the Roslyn–Cle Elum Ridge. Of Northwestern Improvement's three company stores — Cle Elum , Ronald , and Roslyn—the Roslyn store was the biggest and busiest. The store provided food, clothing, hardware, and services for the miners and townspeople. One section of the store provided cobbler services. A woman who grew up during

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744-657: A thickness of only 0.010 inches (0.25 mm). There are some manufacturers who also use actual tin plated steel, which is simply the blackplate steel with a thin coating of bright tin plate adhered to the base metal. Other manufacturers utilize aluminum, as it is rustproof and will last a lifetime. This finish is also an option with dropped ceilings . Sheet metal Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Thicknesses can vary significantly; extremely thin sheets are considered foil or leaf , and pieces thicker than 6 mm (0.25 in) are considered plate, such as plate steel,

806-482: A visitors' center, public events, as well as commercial businesses. The association's renovation plans included safety and accessibility improvements. Various businesses have operated out of the building over the years. In 2017, Heritage Distilling Company, a majority women-owned, family-operated craft distillery in Gig Harbor, opened a tasting room in the old company store building. Tin ceiling A tin ceiling

868-400: Is a heat treatable stainless steel, but it has a lower corrosion resistance than the other grades. It is commonly used in cutlery . The only available finish is dull. Grade 430 is a popular grade, low-cost alternative to series 300's grades. This is used when high corrosion resistance is not a primary criterion. Common grade for appliance products, often with a brushed finish. Aluminium

930-477: Is a common heat-treated structural aluminium alloy. It is weldable, corrosion resistant, and stronger than 5052, but not as formable. It loses some of its strength when welded. It is used in modern aircraft structures. Brass is an alloy of copper, which is widely used as a sheet metal. It has more strength, corrosion resistance and formability when compared to copper while retaining its conductivity. In sheet hydroforming, variation in incoming sheet coil properties

992-567: Is a common problem for forming process, especially with materials for automotive applications. Even though incoming sheet coil may meet tensile test specifications, high rejection rate is often observed in production due to inconsistent material behavior. Thus there is a strong need for a discriminating method for testing incoming sheet material formability. The hydraulic sheet bulge test emulates biaxial deformation conditions commonly seen in production operations. For forming limit curves of materials aluminium, mild steel and brass. Theoretical analysis

1054-468: Is a process of cutting or stamping slits in alternating pattern much like the stretcher bond in brickwork and then stretching the sheet open in accordion-like fashion. It is used in applications where air and water flow are desired as well as when light weight is desired at cost of a solid flat surface. A similar process is used in other materials such as paper to create a low cost packing paper with better supportive properties than flat paper alone. Hemming

1116-404: Is a process of folding the edge of sheet metal onto itself to reinforce that edge. Seaming is a process of folding two sheets of metal together to form a joint. Hydroforming is a process that is analogous to deep drawing, in that the part is formed by stretching the blank over a stationary die . The force required is generated by the direct application of extremely high hydrostatic pressure to

1178-443: Is achieved by simply stripping old paint, treating the metal with a protective base coat, patching minor damaged areas, and repainting. In some cases, where small sections of a ceiling have been damaged, partial restoration is needed. Panels can be easily replaced through companies that still manufacture original design components. If, however, a ceiling requires a historic pattern that is no longer in production, good quality panels from

1240-445: Is also utilized as a catalyst ). These metal sheets are processed through different processing technologies, mainly including cold rolling and hot rolling . Sometimes hot-dip galvanizing process is adopted as needed to prevent it from rusting due to constant exposure to the outdoors. Sometimes a layer of color coating is applied to the surface of the cold-rolled sheet to obtain a decorative and protective metal sheet, generally called

1302-774: Is an architectural element, consisting of a ceiling finished with tinplate with designs pressed into them, that was very popular in Victorian buildings in North America in the late 19th and early 20th century. They were also popular in Australia where they were commonly known as pressed metal ceilings or Wunderlich ceilings (after the main Australian manufacturer Wunderlich ). They were also used in South Africa. Tin ceilings were introduced to North America as an affordable alternative to

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1364-490: Is carried out by deriving governing equations for determining of equivalent stress and equivalent strain based on the bulging to be spherical and Tresca's yield criterion with the associated flow rule. For experimentation circular grid analysis is one of the most effective methods. Use of gauge numbers to designate sheet metal thickness is discouraged by numerous international standards organizations. For example, ASTM states in specification ASTM A480-10a: "The use of gauge number

1426-402: Is clear in column 3 (U.S. standard for sheet and plate iron and steel 64ths inch (delta)). The thicknesses vary first by 1 ⁄ 32 inch in higher thicknesses and then step down to increments of 1 ⁄ 64 inch, then 1 ⁄ 128 inch, with the final increments at decimal fractions of 1 ⁄ 64 inch. Some steel tubes are manufactured by folding a single steel sheet into

1488-569: Is commonly used in chemical processing equipment, light reflectors, and jewelry . Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is corrosion resistant and weldable. It is often used in stampings , spun and drawn parts, mail boxes , cabinets , tanks , and fan blades. Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains high corrosion resistance and weldability. Common applications include electronic chassis, tanks, and pressure vessels . Grade 6061-T6

1550-566: Is discouraged as being an archaic term of limited usefulness not having general agreement on meaning." Manufacturers' Standard Gauge for Sheet Steel is based on an average density of 41.82 lb per square foot per inch thick, equivalent to 501.84 pounds per cubic foot (8,038.7 kg/m ). Gauge is defined differently for ferrous (iron-based) and non-ferrous metals (e.g. aluminium and brass). The gauge thicknesses shown in column 2 (U.S. standard sheet and plate iron and steel decimal inch (mm)) seem somewhat arbitrary. The progression of thicknesses

1612-452: Is generally done in multiple steps called draw reductions. The greater the depth, the more reductions are required. Deep drawing may also be accomplished with fewer reductions by heating the workpiece, for example in sink manufacture. In many cases, material is rolled at the mill in both directions to aid in deep drawing. This leads to a more uniform grain structure which limits tearing and is referred to as "draw quality" material. Expanding

1674-422: Is heated and burnt by the laser beam, cutting the metal sheet. The quality of the edge can be mirror smooth and a precision of around 0.1 mm (0.0039 in) can be obtained. Cutting speeds on thin 1.2 mm (0.047 in) sheet can be as high as 25 m (82 ft) per minute. Most laser cutting systems use a CO 2 based laser source with a wavelength of around 10  μm ; some more recent systems use

1736-423: Is metal working or metal forming process. In this method, stock passes through one or more pair of rolls to reduce thickness. It is used to make thickness uniform. It is classified according to its temperature of rolling: Spinning is used to make tubular (axis-symmetric) parts by fixing a piece of sheet stock to a rotating form ( mandrel ). Rollers or rigid tools press the stock against the form, stretching it until

1798-560: Is not cost effective, due to the cost of making a custom mold for the panel and usually the metal trim that was also used with the original project. More detailed information for repair and replacement of decorative metal ceilings can be found in the National Park Service Technical Preservation Services . Several companies now offer hand-painted finishes for metalwork, as well as a more permanent look that can be achieved with powder-coated finishes. For

1860-435: Is the open width of a V-die or wiping die. The curling process is used to form an edge on a ring. This process is used to remove sharp edges. It also increases the moment of inertia near the curled end. The flare/burr should be turned away from the die. It is used to curl a material of specific thickness. Tool steel is generally used due to the amount of wear done by operation. It is a metal working process of removing camber,

1922-403: Is widely used in sheet metal form due to its flexibility, wide range of options, cost effectiveness, and other properties. The four most common aluminium grades available as sheet metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6. Grade 1100-H14 is commercially pure aluminium, highly chemical and weather resistant. It is ductile enough for deep drawing and weldable, but has low strength. It

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1984-451: The 1870s, being used for shingle roofing, stamped ornamental ceilings, and exterior façades. Sheet metal ceilings were only popularly known as " tin ceilings " later as manufacturers of the period did not use the term. The popularity of both shingles and ceilings encouraged widespread production. With further advances of steel sheet metal production in the 1890s, the promise of being cheap, durable, easy to install, lightweight and fireproof gave

2046-428: The advances in technology, sheet metal cutting has turned to computers for precise cutting. Many sheet metal cutting operations are based on computer numerically controlled (CNC) laser cutting or multi-tool CNC punch press. CNC laser involves moving a lens assembly carrying a beam of laser light over the surface of the metal. Oxygen, nitrogen or air is fed through the same nozzle from which the laser beam exits. The metal

2108-429: The backstop, more advanced machines control the position and angle of the stop, its height and the position of the two reference pegs used to locate the material. The machine can also record the exact position and pressure required for each bending operation to allow the operator to achieve a perfect 90 degree bend across a variety of operations on the part. Punching is performed by placing the sheet of metal stock between

2170-552: The building was privately owned. In the 1990s, the Northwestern Improvement Company Store building was the set for KBHR, the radio station of fictional Cicely, Alaska , in the TV series Northern Exposure . In 2008, the building was used as a furniture store. The Roslyn Downtown Association purchased the building from a developer in 2011 with some funds contributed by the state, and has used the building for its offices,

2232-424: The days of the mining company reminisced about the store: "It was the forerunner of today's malls all under one roof. It had a grocery store, men and women's clothes, a shoe department, yard goods and furniture." Purchases made at the company store were deducted from the miners' paychecks. A lantern would be lit in the store window when work was available. After Northwestern Improvement shut down its mining operation,

2294-409: The effort to collect scrap metal during WWII. Many sheet metal companies began making other products in order to stay in business. In the 21st century, some renewed interest has been shown in tin ceilings. The increase in interest has stemmed from businesses that were renovating and an interest to return to the nostalgia of the turn of the century. Still to this day there exists a manufacturing company by

2356-432: The existing ceiling may be used to create a mold and new customized tin can be pressed. If full restoration is needed, meaning no part of the existing ceiling remains structurally sound, a professional can help design a new ceiling appropriate for the period and structure using existing molds or creating reproductions based on photographic evidence or architectural drawings. This latter method can be extremely expensive, and

2418-466: The exquisite plasterwork used in European homes. They gained popularity in the late 1800s as Americans sought sophisticated interior design. Durable and lightweight, tin ceilings were appealing to home and business owners alike as a functionally attractive design element that was readily available. Important critics such as John Ruskin , George Gilbert Scott , Charles Eastlake and William Morris debated

2480-401: The final stage, the part is punched free from the "web". A typical CNC turret punch has a choice of up to 60 tools in a "turret" that can be rotated to bring any tool to the punching position. A simple shape (e.g. a square, circle, or hexagon) is cut directly from the sheet. A complex shape can be cut out by making many square or rounded cuts around the perimeter. A punch is less flexible than

2542-453: The horizontal bend, from a strip shaped material. It may be done to a finite length section or coils. It resembles flattening of leveling process, but on a deformed edge. Drawing is a forming process in which the metal is stretched over a form or die . In deep drawing the depth of the part being made is more than half its diameter. Deep drawing is used for making automotive fuel tanks, kitchen sinks, two-piece aluminum cans , etc. Deep drawing

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2604-413: The hundred years since the heyday of tin has led to a burgeoning restoration industry. Magazines such as The Old-House Journal were created to offer articles about restoration, repair and installation practices for historic preservation of tin ceilings. Environmental hazards from the lead paint used on turn of the century tin ceilings mean that this is a job for experts in the field. Often restoration

2666-426: The implications of faux materials. These critics believed it was morally wrong and deceptive to imitate another material and blamed the degradation of society towards the "art of shamming" rather than honesty in architecture. Nevertheless, tin ceilings lasted longer than plaster ones and were easier to clean. They encapsulated ideas of democracy, making such decoration available to the middle class majority who supported

2728-407: The leading tin ceiling manufacturer in the late 1800s. At that time, Wheeling Corrugating was a large steel mill that also made products from their steel sheets such as roofing and siding. Sheets of tin were stamped one at a time using rope drop hammers and cast iron molds. Using this method of production, metal was sandwiched between two interlocking tools. The top tool, or "ram," was lifted up by

2790-489: The low end of the market, imitation panels are pressed from plastic or aluminum. Tin is now fashionably used for art work, back splashes, cabinet faces, wainscoting and much more. For over 100 years the tin panel was made with nail rails around the outside of the panel, designed to overlap each other. Panels were nailed into wood furring strips which were prevalent prior to the invention of plywood. Today, nail up panels can be easily brad nailed or hand nailed, into plywood without

2852-455: The machine production. Decorative metal ceilings were first made of corrugated iron sheets, appearing in the United States by the early 1870s. It was during the late Victorian era that thin rolled tin-plate was being mass-produced. Tinplate was originally made from dipping iron in molten tin in order to prevent rust. Later, steel replaced iron as the more cost-effective solution. Tinplate

2914-413: The manual process in the late 17th century. The process of flattening metal sheets required large rotating iron cylinders which pressed metal pieces into sheets. The metals suited for this were lead, copper, zinc, iron and later steel. Tin was often used to coat iron and steel sheets to prevent it from rusting. This tin-coated sheet metal was called " tinplate ." Sheet metals appeared in the United States in

2976-410: The maximum bending force is, F max = k T L t 2 W {\displaystyle F_{\text{max}}=k{\frac {TLt^{2}}{W}}} , where k is a factor taking into account several parameters including friction. T is the ultimate tensile strength of the metal. L and t are the length and thickness of the sheet metal, respectively. The variable W

3038-411: The metal down the required amount to bend it through 90 degrees. Typically, a general purpose machine has an available bending force of around 25 tons per meter of length. The opening width of the lower die is typically 8 to 10 times the thickness of the metal to be bent (for example, 5 mm material could be bent in a 40 mm die). The inner radius of the bend formed in the metal is determined not by

3100-401: The middle-class a significant appetite for sheet metal products. It was not until the 1930s and WWII that metals became scarce and the sheet metal industry began to collapse. However, some American companies, such as the W.F. Norman Corporation, were able to stay in business by making other products until Historic preservation projects aided the revival of ornamental sheet metal. Grade 304 is

3162-445: The most common of the three grades. It offers good corrosion resistance while maintaining formability and weldability . Available finishes are #2B, #3, and #4. Grade 303 is not available in sheet form. Grade 316 possesses more corrosion resistance and strength at elevated temperatures than 304. It is commonly used for pumps , valves , chemical equipment, and marine applications. Available finishes are #2B, #3, and #4. Grade 410

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3224-409: The name of W.F. Norman Corporation that produces original tin ceilings and ornaments from the same rope drop hammers as it once did in 1898. Several other companies offer conventional tin ceilings as well as panels made to fit into a drop-ceiling grid. Tin ceilings were built to last, and in the absence of prolonged moisture damage leading to corrosion, they usually did; however, the wear and tear over

3286-524: The need for the original 1-by-2-inch (25 mm × 51 mm) furring strips. There is also a patented interlocking tin panel that will screw directly into existing drywall/popcorn/plaster ceilings, without the need for extensive plywood installation. Tin panels today are made in 24-by-24-inch (610 mm × 610 mm) and 24-by-48-inch (610 mm × 1,220 mm) sizes for easier handling and one-person installation. Today, most tin ceiling manufacturers actually use recycled blackplate steel in

3348-428: The press contains a V-shaped groove called the die. The upper part of the press contains a punch that presses the sheet metal down into the v-shaped die, causing it to bend. There are several techniques used, but the most common modern method is "air bending". Here, the die has a sharper angle than the required bend (typically 85 degrees for a 90 degree bend) and the upper tool is precisely controlled in its stroke to push

3410-459: The radius of the upper tool, but by the lower die width. Typically, the inner radius is equal to 1/6 of the V-width used in the forming process. The press usually has some sort of back gauge to position depth of the bend along the workpiece. The backgauge can be computer controlled to allow the operator to make a series of bends in a component to a high degree of accuracy. Simple machines control only

3472-425: The role of the machine in the future of art. Tin ceilings were traditionally painted white to give the appearance of hand-carved or molded plaster. They were incorporated into residential living rooms and parlors as well as schools, hospitals and commercial businesses where painted tin was often used as wainscoting. In the 1930s, tin ceilings began to lose their popularity and steel materials became scarce because of

3534-412: The stock takes the shape of the form. Spinning is used to make rocket motor casings, missile nose cones, satellite dishes and metal kitchen funnels. Stamping includes a variety of operations such as punching, blanking, embossing, bending, flanging, and coining; simple or complex shapes can be formed at high production rates; tooling and equipment costs can be high, but labor costs are low. Alternatively,

3596-498: The street. Most of the windows have cast iron shutters which were used during the period for security and fire protection. The Roslyn Miners' Memorial, a statue and plaque engraved with the names of miners who died in the Roslyn coal mines, stands in front of Northwestern Improvement Company Store. A time capsule inside the statue will be opened in 2046. The store was built for the Northwestern Improvement Company,

3658-676: The thinner the metal. Commonly used steel sheet metal ranges from 30 gauge to about 7 gauge. Gauge differs between ferrous ( iron-based ) metals and nonferrous metals such as aluminum or copper. Copper thickness, for example, is measured in ounces, representing the weight of copper contained in an area of one square foot. Parts manufactured from sheet metal must maintain a uniform thickness for ideal results. There are many different metals that can be made into sheet metal, such as aluminium , brass , copper , steel , tin , nickel and titanium . For decorative uses, some important sheet metals include silver , gold , and platinum (platinum sheet metal

3720-424: The workpiece or to a bladder that is in contact with the workpiece, rather than by the movable part of a die in a mechanical or hydraulic press. Unlike deep drawing, hydroforming usually does not involve draw reductions—the piece is formed in a single step. Incremental sheet forming or ISF forming process is basically sheet metal working or sheet metal forming process. In this case, sheet is formed into final shape by

3782-401: Was in plate armor worn by cavalry , and sheet metal continues to have many decorative uses, including in horse tack . Sheet metal workers are also known as "tin bashers" (or "tin knockers"), a name derived from the hammering of panel seams when installing tin roofs. Hand-hammered metal sheets have been used since ancient times for architectural purposes. Water-powered rolling mills replaced

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3844-564: Was not the only sheet metal used to make stamped ceilings. Copper, lead (known as ternplate) and zinc were other common architectural metals in the industry. Between 1890 and 1930, approximately forty-five companies in the United States marketed metal ceilings; most were in Ohio, Pennsylvania, and New York, located along railroad lines that served as the main routes for delivering the pressed metal products directly to contractors. The Wheeling Corrugating Company out of Wheeling, West Virginia, became

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