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Our processing technologies

Technological leader in
double-spindle FSW

Compared to conventional FSW jointing technology the simultaneous two-sided process design provides considerable advantages in terms of reduced production times. The reduction of non-productive time combined with the halving of actual welding time provides potential savings in relation to processes. The simultaneous two-sided process design also has a positive impact on the formation and distribution of residual stresses in welds. This leads to the reproducible achievement of fine surface roughness tolerances.

FSW – the process: Perfect connections thanks to frictional heat
A wear-resistant, rotating tool exerts pressure on the joint area. This generates the required process heat. The fastening of the component in place and a solid backing plate ensure that the horizontal and vertical process forces are absorbed.

The process can be used to join:
Possible types of weld: butt joint, overlap weld, T-joint, fillet weld

Combinations of materials:

• All aluminium alloys, including mixed compounds
• Different materials such as  aluminium-magnesium, aluminium-copper or aluminium-steel joints
• Different production methods
• Castings with profiles
• Plates with profiles
• Different plate thicknesses (tailored blanks)
• Two-dimensional weld seams can be produced using the application variants shown
• Welding speeds: High speeds are typical of the process and contribute significantly to the cost-effectiveness of the method. Preconditions here are close tolerances at the joint, or optimised clamping conditions

The quality that you can expect:

• Level and practically notch-free surfaces
• No gas pores in the joint due to the low process temperature – no molten aluminium
• No hot cracks due to the exerted process forces
• Low distortion due to the low heat input
• High fatigue strength due to the low strain softening and practically notch-free surface

You can find further information about our friction stir welding range of services on the website of our Riftec subsidiary.

Riftec GmbH

Of course the components that we manufacture can also be fitted with additional jointing elements such as rivets and press-in nuts. Riveting robots can do this in the case of large production runs. In the case of smaller quantities they are installed at manual workstations (via monitored riveting devices).

We employ the latest bending technologies – from stretch-bending to roll bending and press brake bending. It is predominantly automotive applications that require a preliminary forming process.

Whenever the quantity to be produced exceeds a critical size, only special machines can be used for production. These are designed for the specific demands of the products and are specialised to such an extent that very short production times can be achieved with minimum production costs. We have experienced partners who can assist us with planning and design.

The production of prototypes is always the first important step for us on the road to the series production order. Through the intensive assessment of the component, we are also able to submit successful series production quotes – at a time when geometric and process engineering optimisation is still possible.