UAZ LIGHT METAL FORGING AND PRESSING PLANT IN KAMENSK-URALSKIY

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00810A007700610003-0
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 46
• Document Creation Date: December 21, 2016
• Document Release Date: September 15, 2008
• Sequence Number: 3
• Content Type: REPORT

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COUNTRY
SUBJECT
PLACE
ACQUIRED
DATE OF
INFO.
CENTRAL INTELLIGENCE AGENCY REPORT
INFORMATION REPORT CD NO.
USSR (Sverdlovsk Oblast)/East Germany
Uaz Light Metal Forging and Pressing
Plant in Kamensk-Uralskiy
THIS DOCUMENT CONTAINS INFORMATION AFFECTING THE NATIONAL DEFENSE
OF THE UNITED STATES, WITHIN THE MEANING OF TITLE 1'S. SECTIONS 793
AND 754, OF THE U. S. CODE; AS AMENDED. ITS TRANSMISSION OR REVEL-
ATION OF ITS CONTENTS TO OR RECEIPT BY AN UNAUTHORIZED PERSON
IS PROHIBITED BY LAW THE REPEODUCTION OF THIS FORM IS PROHIBITED.
forwarded as received.
NO. OF PAGES 28-
NO. OF ENCLS.
(LISTED BELOW)
REFERENCES
SUPPLEMENT TO
REPORT NO. '
THIS IS UNEVALUATED INFORMATION
STATE
ARMY
Attached are
1. Uaz Light Metal Forging and Pressing Plant No. 268, also listed as Aircraft
Parts Plant No. 268, and the nearby Uaz,Alumin m Plant are components of the
Kamensk-Uralskiy light metal industry, which includes a third factory in Uaz,
No. 286, in the Sinarskaya section.
2. Uas should read Uaz throughout the report. Kamensk Uralsk should read 25X1
Kamensk-Uralskiy.
3. Nos. 31 and 32 in the legend to annex 1 are not located on the plan. They
are probably the two small squares in the area semi-enclosed by No. 30.
4. No. 13 in the legend to annex 2 is omtlltted on the plan.
5. Siemag in No. 14+ in the legend to annex 2 is probably the cable
address of Siemans AG.
6. On sketch 13 b in ' 121 a
in which the original plates were to be forged are underlined rather than
executed in blue as stated in the legend.
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the pertinent legends
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25X1
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Location Skettth of the Uas Light Metal Pressing and Forging Plant in Kamensk
Uralsk,
The sketch was prepared on the basis of a city plant of Kamensk Uralsk,
probable scale 1 to 25,000.. It was believed that various scales were used when
the city plan was prepared, because the area and the buildings of the
aluminum works to be twice or more as lar e as 4t
Legend.
1 Uas Light ]fetal Forging and Pressing Plant, Post Box 4, Kamensk Uraisk.
For details, see Annexes 2 to 4.
Ia open area for plants. In November 1953 a large light metal foundry
was under construction there.
2 Area with apartment houses for plant personnel. Brick buildings, many of
them single-story.
2a Area with wooden houses of plant personnel. According to rumors, the bj?
and 2a were to be torn down because the wind constantly blew
red dust from the aluminum plant to this area.
3 Plant administration outside of the plant area
4 Fire department
5 Metallurgical laboratory under construction
6 New administration building under construction, previously planned as
technical school. , .
7 Temporary apartment houses
8 ? Military guard detail
9' Thermal power plant,located ftftw the south than indicated by the city
map which gives the location that had previously been planned. Excavations
and some concreting work indicated that, construction work had been started.
10 Previously planned location of power plant .
11 Water works, probably for drinking water
12 Municipal repair plant for water works (small shed)
13 Aluminum works
l3a Coal dump
13b Lumber dump.
13o Two smokestacks, 80 to 100 m high, at night illuminated by red lamps at
3/4 of their height.
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13d Administration of aluminum works
13e Probably electroly*eecsina4Dqe]3cjls a 1 to 25,000, about 80 m long
14. Apartment houses
15 Fire department
The other buildings of the aluminum works were not identified on the
city plan. The plant was constructed about 1939 and was in a poor .
condition. In the town it was said that working at the plant was not
.healthy and that, therefore, salaries and bonuses were comparatively
high. Even young workers did not stay for more than two years before
going back to a collective farm to remover in fresh air. The plant
was allegedly the largest aluminum works in the USSR. No information
was obtained on the output and the workforce.
16 Approximate location of a freight station in the area marked by the hatched
line, 6 to 8 tracks and a building with an inscription "Uas". A settlement
in this area was not remembered..
17 ,Railroad line with connection to the plant. The line primarily served
agricultural purposes.
18 From this place people were taken to the woods by the train to collect
berries and mushrooms.
19 Previous location of demolished bridge. A connection.to the main line
was probably located more in the north. Cars were still being loaded at
the quarry and left from there.
20 Quarry
21 Railroad line with heavy passsenger and freight traffic. The route of
this line was seen only in the vicinity of the bridge. The fish-bellied
new bridge, a welded steel tube construction was guarded by soldiers.
22 Railroad line with heavy traffic as concluded from steam and smoke seen
in this direction.
Area with a factory and many apartment houses, probably a section of
24 Approximate location ofcTX saidsLbuiti.
25 Branchroad from Kamensk Uralsk - Uas highway leading to pe&yar8%I-*W#Ad
station and to the tube plant probably located in this area.
26, New tube plant, allegedly in operation since 1952.
27 Building complex. Location on city map is correct, temporary buildings
appear too large on the sketch. They have probably been dismantled, because
new modern houses were to be constructed. there connecting Kamensk Uralsk
and U
28 Temporary wooden houses, were probably torn down.
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29 Large modern blocks of 4 -- 5 story apartment houses with courtyards
30 Area with 3 - 4 story houses.) The 25X1
buildings had central heating and hot water. Even in ey were
warm enough to sit in shirt sleeves. Soviets frequently wore pyjamas.
31 School
32 Hospital
33 Stadium
34
35
36
39 Two villas of the directors of the aluminum works
40 School
41 Garden
42 Culture park with pavillions and "summer motion picture theater"
43 Sauna
44 Hospital
45 Rural settlements
46 Cable ferries
47 Sanatorium
A
Luxurious motion picture theater, brick building
Theater park
UNIVERMAG, restaurant, school, kindergarten, insulation station of
hospital, motion picture theater, club of construction workers, and
individual 2. and 3-story wooden apartment houses.
37:nok and bazaar
.38 Stadium
48
"Daohiks ", simple country houses with three rooms, kitchen, bathroom
and large lobby, for the summer vacations of higher plant personnel
starting with the nachalnik (chief) )
49 Militia office of Uas
50 Kamensk district militia office
51 Wooden road bridge was probably replaced by a steel and stone
structure bridge. .
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25X1
25X1
Extrusion Plant and Sheet Rolling Plant of-the Uas Light Metal Forging and
Pressing Plant.
Legend.
Zeche 1 extrusion shop
Zeche 2 - sheet metal rolling plant
l Roller grinding machine
2 Sheet metal packing machine
3 Plate milling machine
4 Packing press for shavings, (part of 3)
5 Slab trimming saw
6 Slab heating furnace
7 Hot rolligg stand (United manufacture)
8 Transformers
9 Furnaces for intermediate annealing
10 Gold rolling works
11 Space for electric generators driving the rolls
12 Repair shop
13 Sheet metal straightening and cutting machine
14 Cold rolling stand (siemag manufacture), obvltously dismantled in Austria
15 Lathe to work on roll bodies
16 Adjusting unit for sheet metal including tempering installation
17 Packing and dispatching department
Except for 14 and 15 all machines were of American origin made by the
United Firm.
Zeche 3 - Extrusion Plant
1 Plant for pressing water
2 Cooling installation
3 Repair shop and material store
4 3,500-ton tube and extrusion press with heating furnace
5 Transformer station
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6 1,500-ton (?) extrusion press with furnace
750-ton extrusion press with furnace
8 500-ton extrusion press with furnace
9 Adjusting and tempering plant
10 Packing station
11 Technical office
12 'Die' store
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Old Forge (Zeche 4) of the Uas Light Metal Forging and Pressing Plant.
Legend.
lY dowers and dressing room
2 Transformer station
3 Shop for pressing water
4 Electrical workshop (Zeche 15)
5' "Pickling plant
6 Material store
Repair shop
9 Tube and extrusion press, 3,500-tons with furnace, same model as the
ona in Zeche 3
10 Disk saws to out raw material
11 Transformer station
12 Preheating furnaces
13 Forging machines
14 Furnace (Junker type with plate convW er)
15 Preheating furnace of 10,000-ton press
16 Forging roll
17 10,000-ton forging press
18 Die heating furnace, (BBC manufacture) cupola furnace (Schachtofen)
from Bitterfeld
19 Junker type double-deck furnace from Bitterfeld
20 5,000-ton extrusion press
21 Heating furnace
22 2,200-.ton forging press
23 Heating furnace
24 3,300-ton forging press'
25 1,250-ton friction press made by Maschinenfabrik Weingarten
26 Two-chamber furnace
27 5,000-ton f
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- 3-
Annex
29 Trimming press (Maschinenfabrik Weingarten mankfacture, dismantled
in Bitterfeld)
30 Tempering unit
31 Band saws with straightening machines (adjustment)
32 Packing plant
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New Forge (Zeche 6) at the Use Light Metal Pressing and Forging Plant.
Legend.
1 Offices
2 Electric switching station
3 Cooling plant
4 Machine shop for the production of pressing water
5 Air compressing station
6 Store and workshop
7 30,000-ton forging press with pressure transmissions and furnaces
8 Tempering furnace and quenching bath
9 15,000-ton foggf,pps x
10 12,000-ton extrusion press with furnace -
11 Homogenizing furnaces
12 Ingot dump
13 5,000-ton extrusion press
14 Special horizontal and vertical press
15 Three-aha erft ee
16 Forging roller
17 Tool making shop, die shop
18 Annealing furnace
19 Pickling plant
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Unfinished Compressor Wheels.
Legend.
Sketch 1:
Laufraeder rotor wheels with about 29 blades. The shape of the
unfinished product permitted machining either of right or left
turning rotors (see black and blue lines). Similar parts, 550
and about 600 mm in dft=VbWvwere produced in the pressing plant
with a monthly output of 3,000 units. The parts were produced by
the 5,000-ton press, the 10,000-ton press or by the 15,000-ton
press. The customer for these eproducts was unknowni
Forged unfinished rotor wheel to be machined as indicated by
the dotted line. The unusual height of the blades effected wrinkling
and recrystallization during the fo.ng process which was to be
eliminated by increasing the working allowance. The parts were
forged on the 3,000-ton press or on the 5,000-ton press in pre-
and final- dieing processes. The monthly output was about 800 units.
The customer was unknown.
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25X1
Sketch 3
Spars Produced tit the Uas Light Metal Forzina and Pressing Plant.
Legend.
Th is were called "lonsherons" ) at the plant 25X1
The two types forged on different dies included one right and 25X1
one left version. Of each type two different versions could be machined.
The parts were forged by the 10,000-ton press at a monthly output of
3,000-units. The receiver of these products was unknown. A record had
to be prepared on each spar produced.
Sketch 4
So-Called Collectors Produced at the Uas Plant.
Legend.
The purpose of these unfinished parts was unknown. They were forged in two
processes:
1 The ingot, 2,000 mm in diameter, was preforged on the 2,200-ton press.
The neck was drawn.
2 Final forging on the 5,000-ton press.
The monthly output was about 2,500 units. The products were sent to the
Kirov Plant in Leningrad.
Similar forgings were being developed in late 1953.
SECRET
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25X1
Sketch
Rotor Wheel Forged at the Uss Plant.
The wheels were produced on the 10,000-ton press and later on the 15,000-ton
press until its second cylinder casing broke. The output of these foxngs
was 3,000 to 4,000 units per month. The customer was unknown. The production
was started in October 1949. The 29 blades of the model reproduced on sketch
were exactly radial.
In early 1952, a person arrived probably from Novosibirsk, at least from
the Asiatic part of the USSR and ordered such forged wheels with similar
dimensions but bent blades. After this order had at first been turned
down by the Uas Plant, the experiments failed that were made by order of
the Ministry of Aviation Industry. Before October 1949, similar unfinished
compressor wheels had been produced with the same output.
Sketch 6.
Unfinished Gde Vanes
The two versions produced were 650 and 800 mm in diameter. The monthly output
was 800 units. A finished guide vane machined from such a ring was seen once.
The customer for these products wqs unknown.
Frame Members
The production of these frame members was started in 1952 with a monthly
output of 100 units which was gradually increased to 1,500 to 2,000 units
per month. They were forged by the 10,000-ton, the 15,000-ton press and
on the 10,000-ton stage of the 30,000-ton press. The purpose and the customer
of these frame parts were unknown. It was believed that they had to meet very
high requirements because samples for tensile tests (fuer Probestaebe iwere
forged to each unit. TA special recrrd had to be prepared on each unit.
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Annex 8
-12- - 2 -
Unfinished Compressor Wheels Produced at the Uas Plant.
Sketch 8 and 8a
The unfinished parts forged were designed so 12 to 14 different
finished parts could be machined. The small number of parts produced
indicated that an experimental series was involved, for which it would
not have paid to build all the tools, i.e. one for each of the 14 different
finished parts. From sketches of the final products it was concluded that
guide vanes or compressor discs respectively for axial-flow compressors
were to bs machined. The first order for the production of these parts was
received in 1951. The number of forgings ordered V"e to be rated for
about 10 axial-flow compressors. A second order for the same number of
unfinished parts was received several months later.
The dimensions of the unfinished parts indicated that finished parts of
sizes as used for 012 type power units could be machined. It was unknown,
however, whether the Soviets had started to produce these component parts
of light metal and not of steel sheets as4t had been done at plant No 2
in Upraiflencheskiyv.,
The unfinished parts were forged on the 30,000-ton press a occasionally
also on the 10,000-ton press. %
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Sketch 9
Reinforced Plate Type Frame Member
This uaaymmyft111 part was a plate reinforced by ribs and had an
aperture (canal) in the center and annexes at the small sides. The plane
rear side was reinforced by some ribs. The thickness of the ribs around
the aperture in the center was big enough to leave enough material after
the machining. It was noticed that the walls of the aperture were not
orthogonal to the plate but had an incline. The angle of this incline was
not remembered. On sketches of the finished part the aperture in the.
center was designated "canal".
The first experimental plates hand forged at the Uas Plant were solid and
were probably milled to their final shape at the aircraft plant. Subsequently
it was ordered that the tools for die forging were manufactured. The first
plates die forged on the 30,000-ton press were seen shortly before
November 1953?
25X1
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Propeller Blades Forged at the Uas Plant.
Sketch 10:
Propeller bUlade, 4,000 mm long including an annex about 300-mm long
for tensile tests.
Sketch 10a: Ingot from which the unfinished propeller blade was forged.
Sketch 10bj Schematic reproduction of the rolling system of the ingot
after the shaft had been attached by the 30,000-ton press.
Sketch 10a: Pressing of shaft.
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Conical Spar Forged at Bitterfeld.
Sketch 11: Section of conical spar.
Sketch 11a: Detailed sketch showing forged conical part and covering
Beplankung)
Sketch 12: Die forging of spar.
a. Two spare were forged in one die from one preforged part,
see sketch 12a for top view of preforged part extending
over both dies.
b. Section of die with two conical spars.
1 Large section
2 Sectionvof smallest part
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Experimental Wing Members
Sketch 13 a: Schematic reproduction of photographic copy of a sketch
Sketch 13 bs Experimental plate forged for the candidate by the Uts plant.-14
The blue numbers indicate the dimensions in which the original
plates were to be forged. This was possible only in a step-by-
step forging process. With a pressure of 2,000 kg being needed
for 1 cm , a total pressure of 120,000 tons would be required
for the pressing of a plate 1 x 6 m. In 19524-50 such plates
were completed.
The results were satisfacbbry.
The side view of plate. On the final version the connecting
pies were to be attached to the part marked by the circle.
Sketch 13 c: Schematic reproduction of the step-by-step forging process
of the rib plate.
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 25X1
Annex 1
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