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Technologia

Fusion welding

It enables permanent joining of two edges of a part or two parts by melting the material in high temperature. We obtain the intended result specified in the technical documentation by very precise selection of the welding temperature, duration of the operation and the appropriate method of the weld execution. Welding is performed using appropriate welding machines, additional materials, and instruments, templates, holders, resistant to high temperatures.

We provide the desired tensile strength for structural joints, high aesthetic values and tightness of the connection (in accordance with the relevant IP standards). We have experienced personnel with appropriate skills and licenses.

We perform welding of the following types:

  • TIG/MMA welding,
  • MIG/MAG/MMA welding,
  • plasma welding.

TIG/MMA welding

TIG/MMA welding is performed using a Kemppi MasterTig welding unit, powered by three-phase electric current. We weld most metals, in particular aluminium and stainless steel, using TIG and MMA methods. We have the possibility of welding with AC, DC +, DC- and MIX TIG currents (it allows welding with mixed AC and DC currents). We ensure obtaining the required connection tightness (in accordance with the relevant IP standards).

Specifications

Work cycle for TIG 300 A
Work cycle for MMA x40 250 A
Range of TIG welding parameters 3 A / 10 V – 300 A / 22 V

Examples of solutions

Audio valve amplifier

A professional, valve, stereo audio amplifier. High-quality materials were used in its production.
The casing is made from chromium-nickel sheets and tube, using the technology of: laser cutting, plasma welding and proper surface grinding, welding or pressing of PEM’s for fixing electronics. The casing also contains turned and milled elements, which were made in accordance with the assumptions of the visual design.
The electronic subassemblies have been assembled and soldered manually to minimize acoustic interference. Testing and tuning was performed using professional music modules generating analogue signals. The final technical acceptance was carried out in a professional listening room on the premises of the company.

MIG/MAG/MMA welding

MIG/MAG/MMA welding is performed using Magnum MIG welders. By means of these devices, we weld alloy steel (MIG), low-carbon steel and low-alloy steel (MAG). We also weld with coated electrodes. This technology requires bench work after the welding process. We ensure obtaining the required connection tightness (in accordance with the relevant IP standards).

Specifications

MIG / MAG welding current 50 ÷ 280 A
MMA welding current 10 ÷ 200 A
Output power 5000 W
Welding voltage 15 ÷ 29 V

Examples of solutions

Subassemblies for hanging the external LCD / LED display

Made of aluminium sheet 4 mm thick, using technology of: punching, edge bending and welding of reinforcements and brackets. Maintaining the dimensions and angle of bending at each point of each element over 2000 mm long and the strength of the connection of welded elements and pressed into the essential element was ensured. This is essential in the further assembly process with a given display screen. Resistance to various atmospheric conditions during operation is ensured by powder coating, with a powder paint appropriate for these conditions.

Brackets that fix LED display elements

Made of 5 mm thick aluminium sheet and pressed screws with metric thread of different diameters, using the following technology: laser cutting, bending, assembly of sleeves on eccentric presses and plasma welding of positioning brackets. They ensure a  very strong connection and are additionally protected against adverse weather conditions by powder coating with appropriate paint.

Plasma welding

Plasma welding is performed using SP-100DC welding machines. We perform plasma welding with DC current, continuous and pulsating, carbon, alloy steels and non-ferrous metals, except aluminium and magnesium, to achieve the high quality and aesthetics of the outer edge of the subassembly. We ensure obtaining the required connection tightness (in accordance with the relevant IP standards). This technology requires the use of a bench work after the welding process. For welding we use elements from thin sheets from 0.4 to 2.0 mm and perform continuous, long line welds. An additional advantage of this technology is the possibility to weld various types of studs and threaded bushes on internal surfaces of parts, with no traces on external surfaces.

Specifications

Welding current 0,5 A - 100 A
Gases used argon (plasma gas)

Examples of solutions

The front panel of the intercom

Made of chromium-nickel sheet with a defined cut of the external surface and a thickness of 2.5 mm with threaded studs for fixing electronic subassemblies. The specific application of the face plate required achieving user-safe external edges, legible and durable inscriptions and aesthetics of workmanship in the production process. Therefore, the following technologies were used: punching, trimming, milling, welding of studs, laser engraving. The fragment of the component presents the result of welding of chromium-nickel threaded studs to a sheet of the same class, from the inside, using a special designed for this welding device with an appropriate tip, applying studs and technological device enabling their appropriate positioning. We obtain a very durable connection resistant to tearing (up to several dozen kilograms), with no trace of such connection on the outer surface of the front panel. The technology can also be used for aluminium sheets and studs.

The front panel of the intercom

Made of chromium-nickel sheet with a defined cut of the external surface and a thickness of 2.5 mm with threaded studs for fixing electronic subassemblies. The specific application of the face plate required achieving user-safe external edges, legible and durable inscriptions and aesthetics of workmanship in the production process.
Therefore, the following technologies were used: punching, trimming, milling, welding of studs, laser
engraving.

SAT transmitter / receiver casing

Made of chromium-nickel sheet with several thicknesses, resistant to sea conditions, and hinges. Several technologies were applied: laser cutting, edge bending and bending on eccentric press, plasma welding, edge surface processing and processes: etching, glass blasting and screen printing. The production process was particularly supervised and controlled to ensure adequate tightness and strength of the casing in operating conditions on vessels.

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