business unit talum castings · catia v5-6: design of dies, clamping devices autocad: design of...
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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: [email protected] page: www.talum-castings.com