Component assembly and testing

Staking and press-fitting are mechanical joining processes for permanently fixing components without additional fasteners. In staking, material is locally plastically deformed to connect components with a form fit, whereas in press-fitting, components are joined with a force fit or form fit by the targeted application of force. Both processes are characterised by high process reliability, reproducibility and cost-effective integration into series production.

Laser welding is a precise joining process in which components are metallurgically bonded by means of focused laser radiation. The high energy density creates a locally confined melt zone with minimal heat input, which reduces distortion and effects on the microstructure. The process enables reproducible, high-strength joints and is particularly suitable for demanding applications in series production.

Resistance welding is a thermal joining process in which components are metallurgically bonded by electric current and the resulting resistance heating. Heating takes place locally at the joint while mechanical pressure is applied to the components at the same time. The process enables short process times and high reproducibility and is particularly suitable for automated series processes with high volumes.

CMT welding (Cold Metal Transfer) is a modified arc welding process in which material transfer is precisely regulated by controlled wire movement and pulsed current flow. Thanks to the cyclical retraction of the wire, droplet transfer is virtually spatter-free with significantly reduced heat input. The process enables reliable, low-distortion joints and is particularly suitable for thin-walled components and different material combinations.

TIG welding (tungsten inert gas welding) is an arc welding process in which the components are joined by means of a non-consumable tungsten electrode under a shielding gas. The arc ensures precise and controlled melting of the material. The process is characterised by very high weld seam quality, exact controllability and clean, spatter-free welding results.

100% visual inspection is a basic inspection applied to all components brazed in our furnaces. It checks whether the filler metal has melted completely, whether the surface has been wetted by the molten filler metal and whether a continuous fillet has formed in the area of the brazed joint. If this inspection is passed, the brazed joint can be considered successful.

Differential pressure and helium testing are established leak testing methods for brazed assemblies, offering different levels of accuracy. In differential pressure testing, the component is pressurised with air or test gas and the pressure drop is measured, which allows leaks in the medium tightness range to be reliably detected. Helium testing, on the other hand, uses helium as a tracer gas and, thanks to highly sensitive detection, can identify even the smallest leak rates. This makes it considerably more precise, and it is used for the most stringent tightness requirements. Leak rates and test pressures are agreed jointly with you.

Gauge inspections are simple, practical test methods for checking the dimensions and function of brazed components. Defined test gauges are used to quickly check whether components are within the specified tolerances and achieve the required accuracy of fit. Despite the low testing effort, the method delivers highly meaningful results and ensures reliable quality assurance in series production.

Metallographic section tests are destructive test methods for the detailed analysis of brazed joints in cross-section. By preparing the sections and evaluating the micrographs under the microscope, filler metal flow, diffusion zones and microstructures can be assessed precisely. The method enables a well-founded evaluation of joint quality and serves as an important basis for process monitoring and optimisation during series production.