business unit talum castings · catia v5-6: design of dies, clamping devices autocad: design of...

Business Unit Talum Castings

Group Talum

Basic information

Year of establishment: 1947

Year of starting up production: 1954

Organization: joint stock company

Number of employees : 1500 / BU Castings 400

Ownership: ELES – 86.25 %

Primary aluminium – 2018: 80.000 t

Aluminium products– 2018: 150.000 t

Net sales revenues – 2018: 365 mio EUR / BU Castings 32 mio EUR

1954 Start-up of Alumina Plant and Electrolysis A

1964 Start-up of Electrolysis B

1988 Start-up of Electrolysis C - Phase I

1995 Start-up with Low pressure-Die-Casting

2003 Start-up of Electrolysis C - Phase II

2004 Start-up with re-melting of secondary aluminium

2006 Start-up with Tilt Gravity-Die-Casting

2009 Start-up of Machining of castings

2010 Installation of 6MWp Solar Power Plant

2013 42 new parts went into serial production

2016 Start-up with High pressure-Die-Casting

2018 23 new parts went into serial production

History

Location

2018 100ha of factory yard, production buildings > 100.000m2

• Intensive growth of castings production with implementation of HPDC

• Increase of value-added of our products with higher complexity and integration of our own knowledge and experiences.

• Diversified product portfolio and the highest quality standards.

• Long tradition, expert knowledge, highly engaged employees.

• Intensive R&D work in co-operation with external research institutions.

• Good geographical location, reliable and long term partnerships.

• Access to financial resources for new investments.

Our strategy and strenghts

Business development

ISO 9001:2001 Quality systems

ISO 14001:2004 Environmental management

OHSAS 18001:2007 Health and Safety Systems

IATF 16949: 2014 Quality systems in automotive

ISO 17025:2015 Accreditation for laboratory testing

Certificates

Development solutions

Technology development• Development of new technologies and upgrading

existence.• Solutions for automatization, robotization and

optimizations of the processes.

Product development• Integrated approach, with the modern tools for

design, simulation and prototyping.

CATIA V5-6: Design of dies, clamping devices

AutoCAD: Design of layouts

MagmaSoft: Core shooting simulations, Casting simulations

VX Elements, Geomagic: 3D Scan

Volume Graphics: Analysis of CT Data

MasterCAM: Programming of CNC machines

Calypso: Programming of CMM machines

Talum is also primary aluminium producer. Beside standard alloys we can offer custom solutions to achieve better material properties:• High hardness without heat treatment > 80 HB 5/250• High hardness with heat treatment > 125 HB 5/250• High tensile strength: Rm > 320 MPa• High elongation: A5 > 8%

Development competences

Main technologies

Casting technologies• HPDC - high pressure die casting • LPDC - low pressure die casting • GTC - gravity tilt casting

Heat treatment (T5, T6):• 50 % of castings are heat treated

CNC machining and assembly• 70 % of castings are CNC-machined.• 20 % of castings are assembled (bearings, bushes,.. )

Other technologies - external• Cracks control• Passivation• Powder coating

Automotive – passenger cars Automotive - commercial vehicles

Engine part - Housing

E-mobility - Battery housingSuspension bracket

E-mobility - Stabilizator Pump housing

Engine part

Transmisson - Electronic

Cab bracket

Products

Motorcycles Non - Automotive

Swing arm

Hub

Seat frame

Oil sump

Filter housing

Electric switcher bracketRopeway wheel

Heat exchanger

Production equipment

Melting• ZPF• MARCONI• Hindenlang

Melt preparation (degassing with Ar):• Foseco

High grade alloys:

• AlSi8Cu3 (226A)

Secondary alloys:

• AlSi9Cu3 (226D)

• AlSi12Cu1 (231)

Primary alloys:• AlSi7Mg0,3

• AlSi10Mg (239 A)

• AlSi10MnMg

Core production

ColdBox technology, max. volume 65dm³

• Laempe (L20-65)

Gravity tilt casting

Robotized pouring of metal and extracting of parts, automatic heating of dies

15 machines

• Senator (KM 4-8)• Talum (KM6)

Low pressure die casting

8 machines

• LPM (single, shutlle system)• Röperwerk (single)

High pressure die casting

3 machines

• Bühler 140 Carat, closing force 1400 tons• Bühler 105 Carat, closing force 1050 tons• Bühler 180 Carat, closing force 1800 tons

Other equipment• Dosing furnace : Striko• Spraying: Wollin• Robot: Kuka• Trimming: Weko, Diesse Presse• Thermocast: Robamat

Feeder cutting and deburring

High volume solutions:

• Robotic cells; 2÷4 robots (Pakman, Talum)

Mid and low volume solutions:

• CNC Milling 3 or 4 axes (Wemas, WD)

• CNC Sawing-milling machines 5 axes (Koyama)

• Manual sawing and grinding

Heat treatment T5, T6• Otto Junker• Rade Koncar• Talum

Surface treatment – shot blastingStainless steel balls• Cogeim• Gostol

Machining

• CNC Milling; Double spindles; 4 and 5 axes (Chiron, Licon)

• CNC Milling; Single spindle; 4 and 5 axes Horizontal (Mori Seiki, Makino, Toyoda, Unior) and Vertical (Doosan)

• CNC Milling; Transfer machine; 6 stages (Gozio)

• CNC Turning; (Doosan)

• Part washer machines (Karl Roll, Hein Hesso, Nerkon)

• Spectrometry (ARL)

• Thermo analyze (Ideco)

• Vacuum test (UDIP)

• Microscopy (Leica)

• X Ray , Computer tomography (GE Seifert, Bosselo)

• CMM measurements (Carl Zeiss, Dea)

• Mechanical properties (Zwick)

• Surface roughness, contour-graph, profile projector (MAR)

• Leak test devices

Laboratory, control equipment

Cleanliness laboratory

• cabinet Pall

• microscope Leica

• cleanliness inspection acc. to VDA 19.1 / ISO 16232

References

Thank you for your attention

Miran Purg, Head of SalesPhone: +386 2 7995 650Mobile: +386 41 755 440E-mail: miran.purg@talum.siHome page: www.talum-castings.com