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TRANSCRIPT
THE REPAIR OF CAST PARTS BY USE OF LASER WELDING
Europe‘s largest service provider with more
than 260.000 cast parts per year incl. rework
Reduction of the reject costs up to 95%
No mechanical machining
repair of moulds
Repair of pore nests by the use of laser welding on a car engine block’s seal face.
Reichle GmbH Gravier- und Laserschweißzentrum was founded in 1981 as an en- graving company and has now about 60 employees. These roots of the precise- ly working engraver are still a fundamental part of the high quality standards we have in the repair of ready- to-mount serial cast parts. Because of breaking into
new markets, the company with 8 divisions has deve- loped to a pan-European service center with its head- quarters in Baden-Wuert- temberg, Germany. Maximum flexibility, exten- sive know-how, best quality and metallurgical apprecia- tion are the key features of the cross-sectoral cooperati- on with our customers.
THE ORIGIN Headquarters of Reichle GmbH Gravier- und Laserschweißzentrum
EUROPE‘S LARGEST SERVICE PROVIDER 260.000 repaired cast parts per year are our best reference
Reichle GmbH
the past years and has been split of in 2013 into a sepa- rate division with the cons- truction of a new produc- tion hall with approximately 2,500 m². Thus, the team of Reichle GmbH has specia- lized its know-how for years in the repair of all cast parts and is now an indispensab- le partner of the European foundry landscape. Throughout Europe more
In the field of the repair of cast parts by the use of la- ser welding, Reichle GmbH has established a significant role. As long ago as 2008, we developed in coopera- tion with a German OEM the repair processes for car and truck engine blocks, which laid the foundation of today‘s success. It began rudimentarily, was successively expanded in
than 40 foundries, 9 ma- chining companies, 4 Tier- 1 and 7 OEMs appreciate their cooperation with us. Thus we repair with more than 20 welding machines annually around 260.000 machined cast parts. There- by we optimize significantly the efficiency and delivera- bility of our customers.
PROBLEMS?
Strongly growing demands, increasingly complex geo- metries and shorter deve- lopment cycles create more and more difficulties in the daily routine of foundries. Pores, blowholes, cracks or leaks arise increasingly and raise partly significantly the scrap rates or provide deli- very bottlenecks. These are often provided with high re- ject costs or can only be cir- cumvent by adding layers.
Especially the destruction of the own or foreign added value through to the re- melting of a machined cast part increases the financial problems of the low yield foundry industry throug- hout Europe. Each foundry, whether for the automoti- ve, power plant or marine applications, is struggling with the same difficulties - some a little better, others slightly worse.
HIGH REJECT COSTS
HIGH REJECT COSTS
RATES
PREDICTABILITY
With our service concept especially developed for cast parts, rejects due to po- res, pore nests, blowholes, cracks or leaks belong to the past. You deliver us only your scrap parts and we re- pair them for you by the use of laser welding technology and special rework and sur- face technologies. Thus we change them into ready-to- mount in-spec parts - wi- thout technical and qua- litative drawbacks; often not visible! At it we have been approved in numerous OEMs and the mostly preva- lent welding ban on the ma-
chined part largely does not apply with our technology. A change in the mechani- cal properties normally and evidently do not take place and often replaces conven- tional caulk. By a 100% fa- bric connecting our process doesn’t have to be seen as a reworking solution, but rather as an efficient com- ponent of the full produc- tion process. We would be happy to advise you first without obligation or create free sample parts for you, or support you in individual re- lease phases with your end users.
SOLUTION!
Every problem has an answer! Also your high scrap costs, quality prob- lems or supply shortages. Do also act efficiently, set on our European-wide approved service and in- crease your profitability with us.
Keeping your deliverability
Quality improvement
A lower supply of your end customers due to poor cast parts batches or processing errors can be circumvented by our repair of cast parts by the use of laser welding.
By the avoiding of the re-melting down of the scrap parts, you act both sustainable for your business and environ- mentally friendly for the society.
By the repair of pores, blowholes and cracks using special welding filler material and the absence of caulk, you in- crease the surface quality and thus the failure risk of the component.
Machined cast parts can often be repaired in our company for a fraction of the costs. From the holder for a few euros through to bearing blocks in the marine sector for tens of thousands of euros to component value.
Reduction of the reject costs up to 95%
ADVANTAGES
No destruction of added-values
Reduction of your stocks
Since you do no longer have to reproduce scrap parts, spe- cial layers are omitted and your free machine capacities are increasing. Thereby new orders which are relevant for your turnover can be processed.
Due to our repairing service all value-added steps remain intact and will not be destroyed: casting, transport, sand blasting, adjustment, machining, impregnation, coating, etc. Therewith debit advices of the downstream value-ad- ded steps also will be bypassed.
By repairing your regularly rejects your safety stocks can be reduced without compromising process reliable delivery capacity.
Due to lower claims and rising parts’ quality you increase the satisfaction of your end customers.
Increasing customer satisfaction
gy, the cast part structure and the filler material is melted in the ran- ge of milliseconds and immediately solidified by the laser beam. Due to this, the casting is barely hea- ted and there is only a very small heat affected zone in the range of a few hundredths of a millimeter. That’s why a thermal distortion of the machined cast part is excluded and even precise fits can be welded dimensionally stable - and largely without changing the mechanical properties. The often prevailing welding ban on machined parts thus does not apply to our special laser welding process.
For over 15 years laser welding is a proven welding technology which is particularly known and omnipre- sent in the field of repair welding of moulds and tools. We take the technology, which was always advanced in our company, as a basis for the repair of your de- fective serial cast parts and proto- types. With modern, hand-held laser wel- ding systems in the power range of 300-500 watt we melt the basic material about your flaw and add additional material by partly spe- cially developed filler metal. The filler metal is combined homoge- neously with the cast part structure and thus closes the original defect. Due to the special pulse technolo-
LASER WELDING
the machining or the imp- regnating and coating.
Only specially trained sur- face technicians conduct the rework in our compa- ny who have already pro- ven a thousand times that a rework in the hundredth range is possible. In addition to classic sealing grooves or flanges, bores, threads, fits and phases are even suita- ble for rework. In the case of very complex geometries or large number of pieces
For the professional repair of your cast parts with flaws on machined surfaces we offer you in addition to the special laser welding pro- cess the dimensionally accu- rate finishing with different surface and sanding tech- niques. Only thus we achie- ve maximum saving poten- tials for your company. So you will convers at a reject component the net costs of the unmachined part as well as the own or foreign per- formed added-value such as
modern 3- and 5-axis ma- chining centers are used ad- ditionally. Both the drawing compli- ant dimensional accuracy and surface characteristics such as roughness valu- es, etc. will be restored. In short, we have the goal that our reworked components are barely indistinguishable from repaired serial compo- nents.
Only specially trained surface technicians or modern 3- and 5-axis machining centers conduct the rework of your machined cast parts.
So you get back at 100% ready-to-mount in-spec parts.
REWORK
company is not necessary!
MOULDS’ REPAIR AND TEXTURING To round out our range of services in the foundry industry, our services are including the repair services around your die-casting moulds or coquilles; equally the surface texturing to affect flow properties and to upgrade components optically.
provement of components. For this we use with the help of 4 ultramodern 5-axis laser systems the special method of laser texturing, replacing the conventional etching process: up to 70% lower processing times, lar- gely cost-neutral and a high level of quality and process standardization.
of hundredth with the help of special surface technolo- gies. Even the surface treat- ment with specially develo- ped blasting techniques is one of our scope. We ensu- re all this processes within a very short lead time to keep your loss of production as low as possible.
As a specialist in the surface area we structure even sur- faces on die-casting moulds to affect flow properties, to postpone pore problems or even to obtain a visual im-
For decades, we repair die- casting moulds and co- quilles and thus help our customers with changes, damages and material attri- tions or extend the lifetime many times over. So we utilize a special pulse, TIG and laser welding process for the material application to obtain the best possible structure connection. Even heat cracks in the surface or material bursts are worked expertly reconditioned, wel- ded and re-milled or ma- nually reworked in a range
before
after
Basically, our special laser welding process is usab- le for all alloys, both iron, gray, spheroidal, vermicu- lar, lamellar- and nodular cast iron as well as alu- minum and magnesium. We already have many successful procedure qua- lifications for application areas in marine, railway and power plant as well as numerous approvals by pan-European OEMs. Even impregnated alumi- num components can be repaired at Reichle by use of special repair methods of laser welding.
The 260,000 cast parts we repair per year, includes wit- hout limitation:
• engine blocks • Cylinder heads • cylinder head covers • gearbox • coupling housing • Pump body • turbo charger • suction pipe • Exhaust manifold • Oil pans • ladder frame • Camshaft frame • engine bearer • wheel axle clamp • air injection manifolds • and much more
ALLOYS AND COMPO- NENT SPECTRUM
POSSIBLE DELIVERY CONCEPTS
Many customers do not see us as a company for the rework of their rejects but almost as serial supplier. By offering the possibility of regular recon concepts, our customers can renounce ad- ditional stints for the post- production of their rejects. We commit ourselves to redeliver the repaired cast parts at a predefined time without any quantitative restrictions. With the use of our unique service concept we become an integral part of the serial production and we further reduce the pri-
mary and secondary reject costs. Likewise, additional services can be ordered optionally: the longer-term storage of out-of-spec parts until the customer approval, sorting and picking, sealing tests, crack tests or even the sand blasting of unma- nufactured contours on the machined cast part. Basically, we adjust the work processes as well as the deli- very concepts individually to the respective requirements of the part, the intended purpose and the customer.
1 BEFORE
AFTERWARDS
For the professional repair of your cast parts with vacancies, pores, blowholes or cracks have to be fully wrought from the basic structure. Subsequently, the patch receives a special welding pre- paration, which is, in connection with the large know-how, responsible for a perfect welded joint of casting alloys. The wrought vacancy will be refilled with an individually matched filler ma- terial, by fusing both the basic struc-
32
4
ture as well as the welding filler for milliseconds using modern laser tech- nology. After that, the material solidi- fies immediately. Following this, different rework and surface techniques allow absolutely precise geometry and drawing con- formal surface without any technical or quality losses - and we can realize this at sealing flanges or grooves, at fittings, bores and threads.
(1) 2 mm wide pore on threefold phased surface at a H7 fit (2) 2 mm wide pore on a phase of a gearbox (3) 3 mm wide pore on a H7 fit (4) Damaged edge to the sealing surface on a gearbox (5) 3 mm deep crack through the entire wall of a cylinder head (6) 3 mm wide pore on a machined sealing surface on a bedplate (7) 1.5 mm wide pore between the cylinder bores on an engine block (8) 2 mm wide pore in a sealing groove (9) 2 mm wide pore on a sealing surface of a pump body (10) Big vacancy on the machined surface incl. bore
7
5
10
6
Gravier- und Laserschweißzentrum
Alte Weberei 6-8
Europe‘s largest service provider with more
than 260.000 cast parts per year incl. rework
Reduction of the reject costs up to 95%
No mechanical machining
repair of moulds
Repair of pore nests by the use of laser welding on a car engine block’s seal face.
Reichle GmbH Gravier- und Laserschweißzentrum was founded in 1981 as an en- graving company and has now about 60 employees. These roots of the precise- ly working engraver are still a fundamental part of the high quality standards we have in the repair of ready- to-mount serial cast parts. Because of breaking into
new markets, the company with 8 divisions has deve- loped to a pan-European service center with its head- quarters in Baden-Wuert- temberg, Germany. Maximum flexibility, exten- sive know-how, best quality and metallurgical apprecia- tion are the key features of the cross-sectoral cooperati- on with our customers.
THE ORIGIN Headquarters of Reichle GmbH Gravier- und Laserschweißzentrum
EUROPE‘S LARGEST SERVICE PROVIDER 260.000 repaired cast parts per year are our best reference
Reichle GmbH
the past years and has been split of in 2013 into a sepa- rate division with the cons- truction of a new produc- tion hall with approximately 2,500 m². Thus, the team of Reichle GmbH has specia- lized its know-how for years in the repair of all cast parts and is now an indispensab- le partner of the European foundry landscape. Throughout Europe more
In the field of the repair of cast parts by the use of la- ser welding, Reichle GmbH has established a significant role. As long ago as 2008, we developed in coopera- tion with a German OEM the repair processes for car and truck engine blocks, which laid the foundation of today‘s success. It began rudimentarily, was successively expanded in
than 40 foundries, 9 ma- chining companies, 4 Tier- 1 and 7 OEMs appreciate their cooperation with us. Thus we repair with more than 20 welding machines annually around 260.000 machined cast parts. There- by we optimize significantly the efficiency and delivera- bility of our customers.
PROBLEMS?
Strongly growing demands, increasingly complex geo- metries and shorter deve- lopment cycles create more and more difficulties in the daily routine of foundries. Pores, blowholes, cracks or leaks arise increasingly and raise partly significantly the scrap rates or provide deli- very bottlenecks. These are often provided with high re- ject costs or can only be cir- cumvent by adding layers.
Especially the destruction of the own or foreign added value through to the re- melting of a machined cast part increases the financial problems of the low yield foundry industry throug- hout Europe. Each foundry, whether for the automoti- ve, power plant or marine applications, is struggling with the same difficulties - some a little better, others slightly worse.
HIGH REJECT COSTS
HIGH REJECT COSTS
RATES
PREDICTABILITY
With our service concept especially developed for cast parts, rejects due to po- res, pore nests, blowholes, cracks or leaks belong to the past. You deliver us only your scrap parts and we re- pair them for you by the use of laser welding technology and special rework and sur- face technologies. Thus we change them into ready-to- mount in-spec parts - wi- thout technical and qua- litative drawbacks; often not visible! At it we have been approved in numerous OEMs and the mostly preva- lent welding ban on the ma-
chined part largely does not apply with our technology. A change in the mechani- cal properties normally and evidently do not take place and often replaces conven- tional caulk. By a 100% fa- bric connecting our process doesn’t have to be seen as a reworking solution, but rather as an efficient com- ponent of the full produc- tion process. We would be happy to advise you first without obligation or create free sample parts for you, or support you in individual re- lease phases with your end users.
SOLUTION!
Every problem has an answer! Also your high scrap costs, quality prob- lems or supply shortages. Do also act efficiently, set on our European-wide approved service and in- crease your profitability with us.
Keeping your deliverability
Quality improvement
A lower supply of your end customers due to poor cast parts batches or processing errors can be circumvented by our repair of cast parts by the use of laser welding.
By the avoiding of the re-melting down of the scrap parts, you act both sustainable for your business and environ- mentally friendly for the society.
By the repair of pores, blowholes and cracks using special welding filler material and the absence of caulk, you in- crease the surface quality and thus the failure risk of the component.
Machined cast parts can often be repaired in our company for a fraction of the costs. From the holder for a few euros through to bearing blocks in the marine sector for tens of thousands of euros to component value.
Reduction of the reject costs up to 95%
ADVANTAGES
No destruction of added-values
Reduction of your stocks
Since you do no longer have to reproduce scrap parts, spe- cial layers are omitted and your free machine capacities are increasing. Thereby new orders which are relevant for your turnover can be processed.
Due to our repairing service all value-added steps remain intact and will not be destroyed: casting, transport, sand blasting, adjustment, machining, impregnation, coating, etc. Therewith debit advices of the downstream value-ad- ded steps also will be bypassed.
By repairing your regularly rejects your safety stocks can be reduced without compromising process reliable delivery capacity.
Due to lower claims and rising parts’ quality you increase the satisfaction of your end customers.
Increasing customer satisfaction
gy, the cast part structure and the filler material is melted in the ran- ge of milliseconds and immediately solidified by the laser beam. Due to this, the casting is barely hea- ted and there is only a very small heat affected zone in the range of a few hundredths of a millimeter. That’s why a thermal distortion of the machined cast part is excluded and even precise fits can be welded dimensionally stable - and largely without changing the mechanical properties. The often prevailing welding ban on machined parts thus does not apply to our special laser welding process.
For over 15 years laser welding is a proven welding technology which is particularly known and omnipre- sent in the field of repair welding of moulds and tools. We take the technology, which was always advanced in our company, as a basis for the repair of your de- fective serial cast parts and proto- types. With modern, hand-held laser wel- ding systems in the power range of 300-500 watt we melt the basic material about your flaw and add additional material by partly spe- cially developed filler metal. The filler metal is combined homoge- neously with the cast part structure and thus closes the original defect. Due to the special pulse technolo-
LASER WELDING
the machining or the imp- regnating and coating.
Only specially trained sur- face technicians conduct the rework in our compa- ny who have already pro- ven a thousand times that a rework in the hundredth range is possible. In addition to classic sealing grooves or flanges, bores, threads, fits and phases are even suita- ble for rework. In the case of very complex geometries or large number of pieces
For the professional repair of your cast parts with flaws on machined surfaces we offer you in addition to the special laser welding pro- cess the dimensionally accu- rate finishing with different surface and sanding tech- niques. Only thus we achie- ve maximum saving poten- tials for your company. So you will convers at a reject component the net costs of the unmachined part as well as the own or foreign per- formed added-value such as
modern 3- and 5-axis ma- chining centers are used ad- ditionally. Both the drawing compli- ant dimensional accuracy and surface characteristics such as roughness valu- es, etc. will be restored. In short, we have the goal that our reworked components are barely indistinguishable from repaired serial compo- nents.
Only specially trained surface technicians or modern 3- and 5-axis machining centers conduct the rework of your machined cast parts.
So you get back at 100% ready-to-mount in-spec parts.
REWORK
company is not necessary!
MOULDS’ REPAIR AND TEXTURING To round out our range of services in the foundry industry, our services are including the repair services around your die-casting moulds or coquilles; equally the surface texturing to affect flow properties and to upgrade components optically.
provement of components. For this we use with the help of 4 ultramodern 5-axis laser systems the special method of laser texturing, replacing the conventional etching process: up to 70% lower processing times, lar- gely cost-neutral and a high level of quality and process standardization.
of hundredth with the help of special surface technolo- gies. Even the surface treat- ment with specially develo- ped blasting techniques is one of our scope. We ensu- re all this processes within a very short lead time to keep your loss of production as low as possible.
As a specialist in the surface area we structure even sur- faces on die-casting moulds to affect flow properties, to postpone pore problems or even to obtain a visual im-
For decades, we repair die- casting moulds and co- quilles and thus help our customers with changes, damages and material attri- tions or extend the lifetime many times over. So we utilize a special pulse, TIG and laser welding process for the material application to obtain the best possible structure connection. Even heat cracks in the surface or material bursts are worked expertly reconditioned, wel- ded and re-milled or ma- nually reworked in a range
before
after
Basically, our special laser welding process is usab- le for all alloys, both iron, gray, spheroidal, vermicu- lar, lamellar- and nodular cast iron as well as alu- minum and magnesium. We already have many successful procedure qua- lifications for application areas in marine, railway and power plant as well as numerous approvals by pan-European OEMs. Even impregnated alumi- num components can be repaired at Reichle by use of special repair methods of laser welding.
The 260,000 cast parts we repair per year, includes wit- hout limitation:
• engine blocks • Cylinder heads • cylinder head covers • gearbox • coupling housing • Pump body • turbo charger • suction pipe • Exhaust manifold • Oil pans • ladder frame • Camshaft frame • engine bearer • wheel axle clamp • air injection manifolds • and much more
ALLOYS AND COMPO- NENT SPECTRUM
POSSIBLE DELIVERY CONCEPTS
Many customers do not see us as a company for the rework of their rejects but almost as serial supplier. By offering the possibility of regular recon concepts, our customers can renounce ad- ditional stints for the post- production of their rejects. We commit ourselves to redeliver the repaired cast parts at a predefined time without any quantitative restrictions. With the use of our unique service concept we become an integral part of the serial production and we further reduce the pri-
mary and secondary reject costs. Likewise, additional services can be ordered optionally: the longer-term storage of out-of-spec parts until the customer approval, sorting and picking, sealing tests, crack tests or even the sand blasting of unma- nufactured contours on the machined cast part. Basically, we adjust the work processes as well as the deli- very concepts individually to the respective requirements of the part, the intended purpose and the customer.
1 BEFORE
AFTERWARDS
For the professional repair of your cast parts with vacancies, pores, blowholes or cracks have to be fully wrought from the basic structure. Subsequently, the patch receives a special welding pre- paration, which is, in connection with the large know-how, responsible for a perfect welded joint of casting alloys. The wrought vacancy will be refilled with an individually matched filler ma- terial, by fusing both the basic struc-
32
4
ture as well as the welding filler for milliseconds using modern laser tech- nology. After that, the material solidi- fies immediately. Following this, different rework and surface techniques allow absolutely precise geometry and drawing con- formal surface without any technical or quality losses - and we can realize this at sealing flanges or grooves, at fittings, bores and threads.
(1) 2 mm wide pore on threefold phased surface at a H7 fit (2) 2 mm wide pore on a phase of a gearbox (3) 3 mm wide pore on a H7 fit (4) Damaged edge to the sealing surface on a gearbox (5) 3 mm deep crack through the entire wall of a cylinder head (6) 3 mm wide pore on a machined sealing surface on a bedplate (7) 1.5 mm wide pore between the cylinder bores on an engine block (8) 2 mm wide pore in a sealing groove (9) 2 mm wide pore on a sealing surface of a pump body (10) Big vacancy on the machined surface incl. bore
7
5
10
6
Gravier- und Laserschweißzentrum
Alte Weberei 6-8