From prototyping
to series production

Our welding isrenowned for:

  • excellent surface finish
  • high static and dynamic strength
  • absence of pores
  • consistency
  • good formability

RIFTEC - We weld aluminium

RIFTEC’s friction stir welds are stronger and tougher than conventional fusion welds. One of the reasons for this is that with our process, substantially less heat is introduced into the component than with other processes. Instead, we use high process forces, which in turn require firm support of the pieces to be welded. We therefore carefully study every component beforehand to see whether the joint geometry is suitable for friction stir welding.

 

Our services range from individual consulting with construction suggestions regarding material procurement, essential pre- and post-processing, assembly, the actual aluminium welding and quality inspection up to the logistics of the completed components. All of these services are performed to the most important quality standards. You can of course also simply give us your components and we will return them to you friction stir welded.

 

What we can weld with FSW:

Components can consist of almost any aluminium alloy or of other light and non-ferrous metals such as magnesium or copper. Dissimilar joints such as Al-Cu or Al-Mg can also be welded. We even weld stainless steel to aluminium, if the two material grades and the geometry are a good match.

 

With regard to component size, it is usually the operating space of the machine that is the limiting factor. We can weld up to 2.9 m in one clamping position; depending on the machine, several successive clamping positions are possible. For multidimensional work, the maximum component height is about 900 mm. At RIFTEC, the penetration depth for FSW ranges from 0.8 to 20 mm, but these are merely guide values – it depends on the alloys in question and the component geometry.

 

Similarly, the welding speed and the process forces applied greatly depend on the component, the material and the geometry. Nevertheless, depending on the welding plant used, the welding speed can be up to 4,000 mm/min and the force applied up to 50 KN

Benefit for the environment and the team

we weld without shielding gas and without filler metal

more

One-offs and prototypes

One-offs and prototypes

One-offs and prototypes

There is magic in every beginning…

Hermann Hesse

That is why we are pleased to be a part of your construction phase. We will gladly assist you with advice on the design of the joint geometry leading up to the first trial welds of your project. It can then be aligned with the FSW process without losing sight of the requirements your component has to meet.

 

But even in projects that are already under way, the welding process initially selected may become questionable. This is often because of quality concerns, with too many rejects or problems further down the processing line. In such cases we are happy to play a consulting role, check whether friction stir welding is a suitable alternative and suggest changes if necessary.

 

In the next step – or, if this is your starting point, the first step – we weld your prototypes or sample components, including machining before and/or after welding, if required. We inspect the properties of the weld, draw up the necessary production documents and supply the relevant technical reports and test certificates for your components.

Series components

Series components

Series Components

Tin Lizzy" paved the way:

A high degree of productivity through top quality and clear design. That is exactly what we demand from our friction stir welded series components. You benefit especially from the high degree of consistency of the process, because unlike in conventional welding processes, each weld we make is identical to another. That is why the friction stir welding process is the only process to consider for industrial mass production of aluminium components.

 

RIFTEC has five different welding plants for series production. We can do large, fast, thick-walled, multidimensional and complex – depending on the component and the customers’ requirements.

 

Our new automated production cell for friction stir welding, processing and pressure testing radiators for the automobile industry is unique. It is currently manufacturing one hundred and fifty thousand radiators a year – and counting. Because of the high demand, a second identical production cell is already being planned.

 

In series production, we test the weld quality directly and during the same shift in our in-house testing laboratory. Short routes for rapid reactions

Modules

Modules

Modules

"A group of individual parts that is integrated into the end product as a unit”

 

In accordance with this definition, we endeavour to make the greatest possible contribution to the unity of your welded module. We take care of the coordination and execution of many basic machining steps associated with friction stir welding for you, so that you can get a finished module from us.

 

In most cases, the first step is procurement of the starting materials. As part of the Austrian HAI Group, we have internal access to the highest level of aluminium expertise – our extrusion plants in Germany and Austria are some of the most modern in Europe and are renowned for different kinds of profiles.

 

A second step is the machining before and after welding. Over the years, we have invested heavily in this aspect – in machines and in well-trained employees.

 

We assemble add-ons for many customers, such as radiators for electric cars or drying trays for drying foodstuffs. For decorative surfaces, we cooperate with a fixed supplier base, which enables us to offer a range of anodised or plastic-coated surfaces.

 

We inspect the quality of our welds by destructive testing – grinding, bending or tensile tests – or non-destructively (in particular with radiators) by pressure testing.

We also measure, serialise, package and dispatch for you, and we organise many more prior and subsequent steps upon request.

And remember

Even when time is of the essence, you have RIFTEC at your side as a contract welder! As an independent service provider, we can even do irregular series or production start-ups for you at short notice. You can also call on us if you experience a sudden increase in capacity or as assurance against production failures.