FOCUS ON WELDING
Feasibility studies and quality controls
Aluminium transformer housing for an electric locomotive.
Before new components go into production, ALLUCAN AG conducts comprehensive feasibility studies. First, the design drawings are checked in close collaboration with the customer and adapted, if necessary, until the ideal welding conditions for the welding sequence and the layer build-up are guaranteed.
During the subsequent process and work sample tests, a range of test methods are used to ensure the quality of the weld seams including visual inspection, dye penetration, ultrasonic and X-ray tests. All of these are carefully documented to prove compliance with the standards. These tests are further complemented by technological material tests and the production of micro- and macrosections.
Once the feasibility tests are complete, the company produces painted and unpainted component samples for First Article Inspection( FAI) by the customer. Series production can only start once the customer has given its approval on-site at ALLUCAN’ s Bremgarten factory in Switzerland.
Before finished components are ready for picking, they undergo a detailed final inspection which includes a digital 3D measurement using a special mobile camera to check for possible dimensional deviations and distortions. The end products are only delivered once all tolerances satisfy the customer’ s requirements.
Enclosures and housings
ALLUCAN AG manufactures lightweight transformer enclosures and special housings from aluminium, which are primarily used in high-performance locomotives and high-speed trains. These aluminium housings increase the energy efficiency of locomotives, while also
Mobile 3D component measurement during final inspection.
Above and below: Testing components at ALLUCAN AG.
complying with strict safety requirements. This requires precisely positioned welds with consistent geometries and layer build-ups. Up to 20 or more weld layers must be produced, depending upon the material thickness.
“ Welding often takes place using the TIG welding process, which has several advantages. For example, TIG enables the welder to produce flawless, flat welds which guarantee an optimum basis for the subsequent layer build-up. The smooth TIG beads minimize the risk of notch effects, which enhances the structural integrity of the welded joints,” explained welding specialist, Fronius.
“ MIG welding, which is particularly suitable for thicker materials, is used to build up the layers. It enables high welding speeds and offers good control over the weld. This is where our iWave 500i AC / DC Multiprozess PRO welding machine excels, guaranteeing welding quality for every single weld. One particular benefit is the rapid and straightforward changeover from TIG to MIG and vice versa,” continued Fronius. ALLUCAN AG CEO, Markus Jäger, highlighted the benefits of the iWave welding system for his company and the components
Markus Jäger, that it welds.
CEO, ALLLUCAN AG.
“ We can switch flexibly between the different welding processes just by pressing a button. This flexibility, particularly the savings in working time and space requirements, is greatly beneficial. All Fronius welding machines stand out due to their exceptional service life and stability, and especially noteworthy is the availability of spare parts over many years which ensures that we can continue to rely on the devices in the long term. That’ s why they are so popular with us,” confirmed Jäger.
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