- After casting the raw castings are separated from the cluster, the gate is ground off and the raw parts are blasted and fettled. The cut bars and crosses of the cluster represent recycling material and can be remelted. The finished castings can either be delivered as raw parts or be further refined by casting processing.
- At the beginning of the raw part processing there is the mechanical processing - a machining production process. In this process the castings are turned, milled or ground. Here, we have an extensive range of CNC machining centres at our disposal in-house and long-standing business relationships with reliable external suppliers. Through the acquisition of the majority shareholding in B² smart precision, our manufacturing portfolio has expanded, beside casting processing, by parts milled from solid and the CNC machines required for this purpose.
- After mechanical processing, your castings can be mounted into ready-to-install assemblies in our assembly department.
Assembly to components
- To make your procurement as effective as possible, we offer you the assembly of individual elements into assembly groups. In addition to conventional joining methods such as riveting, screwing or TIG welding, we also use modern welding techniques such as laser welding and EB welding. This makes us a competent supplier of ready-to-install parts and components.
Details about our welding procedures:
When welding metal a joint is created by partially melting the basic material. This can take place under vacuum or atmospheric conditions. As required, additional filler metal of equal or higher value is fed into the joint area. Joining a component by welding is determined by the properties of the materials (weldability of the materials) and the design of the component (welding safety of the design). The weldability describes the reactions of the alloy to the heating of the welding. With a suitable material, the chemical-physical properties are only slightly influenced by the heating. Depending on the material compositions of the alloy as well as the design of the component, the geometry and size, a suitable procedure is selected.
TIG means tungsten inert gas. TIG welding is a protective gas welding process which in turn, belongs to the arc and fusion welding processes. The electric arc burns between the non-melting tungsten electrode and the component. Despite its intensity this arc can be guided well. The protective gas argon forms an inert atmosphere that protects the area of the welding seam from reactions with the environment and oxygen (oxidation). Stainless steel, steel, titanium or copper alloys are welded with direct current. Alternating current, on the other hand, is used for aluminium alloys, for example.
TIG welding can be carried out both with and without additives. Particularly high seam qualities can be achieved as well as low scaling. This leads to clean welding seams with a narrow weld zone. Further reworking is usually not necessary. The advantages of our technology, beside the partial automation which ensures high flexibility, quality and process stability, are the repeatability and the variety of weldable joints. Many different materials and alloys can be joined using this method. It can be used in all sectors such as automotive, industry and mechanical engineering.
Laser beam welding
Laser stands for Laser Amplification of Stimulated Emission of Radiation and means light amplification by stimulated emission of radiation. Laser beam welding is a type of laser welding that is often used in the automotive industry. In laser welding two components are joined together. Both abutting edges of the components are melted by the laser and joined at the seam by the melt produced there. The laser bundles the light energy on one surface through the focusing optics. This produces a very high concentration of energy. The temperature rises on the surface of the workpiece and the melt necessary for the joining process is formed. The movement of the laser and the rapid cooling result in a hard welding seam.
This welding process can be carried out with or without filler metals. It can be executed under normal atmospheric conditions or under vacuum. An inert atmosphere brought about by argon protects against reactions with the ambient air. No further rework is required. All weldable materials can be joined in this process, including unalloyed, low-alloy and high-alloy steels, austenitic steels, aluminium alloys, nickel or titanium alloys.
The advantages are, among others,
- a low thermal distortion due to a narrow heat-affected zone (HAZ) and a low heat input,
- a high degree of automation to ensure economic efficiency,
- process stability and process reliability as well as a fast driving speed of the laser.
Due to the narrow welding seams the machined parts are also suitable for visible surfaces. Mixed joints of different materials can be joined well with each other through this procedure.
Electron beam welding (EB welding)
EB welding is the most accurate welding procedure. In this process, kinetic energy of an electron beam is converted into heat. The process takes place under vacuum. The beam source generates a beam that is as thin and little divergent as possible. For wider seams, this can then be slightly widened and broadened. Free electrons are needed to create an electron beam. Tungsten serves as the electron source here. The electrons are accelerated by tension. The bundled electron beam leads to melting at the joining of the workpiece. This is due to the conversion of the kinetic energy of the electrons into heat. The magnets guide and steer the electrons in the desired direction. This allows the electron beam to be used for precise welding.
The electron beam creates a vapour capillary in the material. This makes it possible to melt the joint not only superficially but also deeply. With gap-free positioning of the joint the welding is possible without filler metal. The heat-affected zone is very narrow, as only the joint is heated. Therefore the distortion is very low. The joining of high-temperature resistant special alloys made of steel, aluminium, copper or titanium, as well as other light and heavy metals is possible. This process is suitable for a wide range of workpieces and alloys, but especially for technically demanding joints and alloys, as high precision and quality of the weld can be achieved. Among other things, it is used for components in the automotive industry to weld nickel-based alloys such as INCONEL or MAR. Electron beam welding is used in mixed joints for welding corrosion-, chemical- and heat-resistant and high-temperature metallic superalloys. Other areas of application include aerospace, mechanical engineering and medical technology. Advantages of our process are the high reproducibility, automation and process stability through integrated series monitoring.
Survey of advantages:
● Low heat input and narrow melting and heat-affected zone (HAZ)
● Precision with high welding speed at the same time
● Joining of demanding joints
● Clean, oxidation-free and reproducible environment in vacuum
● High degree of automation, series stability and process reliability
● No reworking necessary
Refinement of the cast products
Refinements are often not necessary due to our variety of materials. Nevertheless, we offer you various processes for further refinement in addition to casting processing. These include coating processes as well as heat and surface treatments such as tempering, hardening, annealing, pickling, galvanising, nitriding, lacquering and anodising. The services of our partners complete the total package for you.