Closed die forgings
FOR THE COMMERCIAL VEHICLE INDUSTRY, MINING,
THE OIL AND GAS INDUSTRY, GENERAL MECHANICAL
ENGINEERING AND AGRICULTURAL MACHINERY
Buderus Edelstahl
Buderus Edelstahl
CONTENTS
Buderus Edelstahl
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Products
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Production
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Quality
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CLOSED DIE FORGINGS FOR
HIGH DEMANDS
BUDERUS EDELSTAHL — QUALITY FROM A SINGLE SOURCE:
The entire production process, from melting through to produc-
tion of the end product, takes place at the Wetzlar site. This also
applies to our high-quality closed die forgings. We melt the
initial material from high-quality scrap steel in our own steel
plant, process the ingots in the rolling plant and forge them in
our own closed die forging facility. The heat treatment, finishing
and final inspection also take place directly on-site. All production steps are precisely coordinated. This saves time, makes the
product hand-over easier and makes us flexible and reliable.
The short communication paths between quality assurance,
production planning, production and sales guarantee smooth
order processing.
The expectations of our customers have the highest priority at
every stage. As a competent partner, we are available for all
application queries and work with our customers to find suitable
solutions for specific requirements. We produce tried and tested
standard products, as well as individual steels, which we develop
according to the specifications of our customers. Small batch
sizes are no problem for us. The success of Buderus Edelstahl
is based on a high level of flexibility, reliability and service, as
well as on a transparent quality assurance system.
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3
Products
Production
PROGRESS THROUGH QUALITY
Our closed die forging plant plans and produces drive and axle
components for the commercial vehicle industry, as well as com
plex geometrical structures for construction and agricultural
machinery, the offshore sector, mining technology, the oil and
gas industry, fittings and general mechanical engineering.
Our diverse product range includes shafts, gear wheels, stub
axles, bearing rings and flanges. Wear parts from Buderus
Edelstahl have an excellent reputation all over the world. The
use of high-grade steels means that our products offer a particularly long service life.
Each of our products is unique. We work with our customers
to develop individual solutions and produce these closed die
forgings tailored to their specific needs. We fulfill complex specific
requirements with regard to form, tolerances and material.
The fact that we have our own melting plant is a particular
advantage, as it enables us to respond flexibly to customer
requests and requirements and to meet the desired delivery
times reliably. Our special service: The closed die forgings are
shipped in accordance with their relevant packaging regulations.
The benefits of our closed die forgings:
narrow tolerance limits
echanical properties adapted precisely to the
m
relevant use
high degree of process reliability during production
s table quality features and part traceability over
many years
c omplete dimensional accuracy in accordance with
drawing specifications
Throughout the development process, our employees from the
fields of technology, product management and sales are in con
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With a furnace capacity of 100 to, Buderus Edelstahl melts the
steel in its own electric steel plant. For this, we use high-quality
scrap steel from the recycling cycles in Germany and Europe.
After tapping, the steel is deoxidized and degassed in the secondary metallurgy process (LF-VD/VOD plant) and either deep
desulphurized or set to a controlled sulphur content depending
on the requirements. The steel is bottom cast in moulds with
hot top insulation to rolling ingots weighing between 2.8 and
4.6 to.
In the rolling plant, the heated ingots are rolled on ingot and billet
lines to the desired cross-sections and round dimensions. After
the cooling, the ingots undergo several quality optimization
processes: They are aligned, blast descaled, checked for cracks
and ultrasonically tested. Before the hand-over to the closed
die forging plant, the products are subjected to a a full spectroscopic inspection.
just-in-time deliveries
CLOSE TO THE CUSTOMER
We have long-term, trusting relationships with our customers
based on a close and solution-orientated cooperation. Our
engineers, metallurgists, application technicians and sales
representatives have extensive expertise in the field of materials,
a detailed knowledge of the markets and complex technologies
and a high level of personal commitment. This is what makes
us an extremely reliable partner.
QUALITY STARTS EARLY ON
stant dialogue with the customer. First of all, our engineers
and metallurgists assess the customer requests for technical
feasibility. They bring wishes and reality together on the monitor.
They then simulate the material flow and design the suitable
tools. Once all questions have been clarified systematically
and a concrete approach has been defined for how the desired
result can be achieved, we move to the next step: production.
FROM 2 TO 220 KG
We produce closed die forgings on six press lines with compres
sion forces between 25 and 100 MN. These pressing modules
produce closed die forgings in a weight range from 2 to 220 kg
as unmachined parts or mechanically processed finished parts
in accordance with their specific requirements.
are process-monitored and computer-controlled. Some of the ma-
chines are fully automated and equipped with robot technology.
Induction heating plants heat up the sawn billet sections to forg
ing temperature. A hydraulic preforming press pre-forms the
billet sections before they are forged on the main unit. The flashing press gives the forged parts their final shape. The systems
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Production
Quality
MODERN SYSTEM TECHNOLOGY
We invest regularly in our presses to keep them at their high
technical standard. In 2014 alone, we spent 5.5 million Euro on
optimising our fully automated 100 MN press line.
In a continuous process, we produce challenging chassis and
drive components, predominantly for the European commercial
vehicle industry. The entire production process is controlled
centrally via computers, from the material store to the finished
product. Short set-up times thanks to automatic tool change
systems mean that different part families can be forged on
this line. Under optimal conditions, we can achieve a production
output of up to 8 to per hour.
CERTIFIED TESTING
Closed die forgings from Buderus Edelstahl play a key role in the
safety of the customer product — for example as a part in a truck
axle. Buderus Edelstahl lives up to this immense responsibility.
Our metallurgists and engineers are familiar with the limits and
capabilities of all steel grades. They know the relevant flow
characteristics and the fibre orientation in the forging process
and control them precisely.
Our quality assurance system specifies all quality-relevant process steps and inspection points in detail. Each production step
is checked precisely and documented clearly — from the melting
of the steel through to the forming processes and delivery.
The integrated management system at Buderus Edelstahl
GmbH is certified in accordance with ISO 9001, ISO/TS 16949,
ISO 14001 and ISO 50001.
OUR PRODUCTION PROCESS
We carry out extensive checks on all our closed die forgings
and have additional testing facilities, such as Magna-Flux systems and 3D measuring machines and scanners. In addition
to the traditional material tests, such as tensile tests, hardness
tests, structure and purity level tests in accordance with national
and international standards, we also check fracture-mechanical
parameters (e. g. KIC), carry out impact tests according to
Brugger and tests with the scanning electron microscope and
EDX/WDX analyses in our testing laboratory. The testing laboratory is certified by “Deutsche Akkreditierungsstelle GmbH
(DAkkS)” in accordance with DIN EN ISO/IEC 17025.
REFINED IN FIRE
Each component can then undergo heat treatment depending
on the customer specifications and use. Our metallurgists and
engineers have extensive expertise in the field of materials and
help to find the right solution for optimal further processing.
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There is a wide range of options available, which are
tailored to the individual requirements of the customer:
tempering
BY-treatment
FP-annealing
BF-annealing
soft annealing
spheroidizing
normalizing
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CLOSE TO THE CUSTOMER ALL OVER THE WORLD
Buderus Edelstahl GmbH is a renowned German manufacturer of high-grade special steels.
Both our standard steels and our special steels have an excellent reputation all over the world.
With more than 50 sites, service centres and product warehouses, we guarantee close
cooperation and quick reaction times for our customers.
Special steels from Buderus Edelstahl are used in vehicle and drive technology, plant and machine
construction, as well as tool and mould production. We deliver quality products from a single
source for these high-tech sectors:
Tool steel
Special engineering steel
Open die forgings
Drop forged components
Hot and cold-rolled strips
Semi-finished products
Hardness comparison plates
Buderus Edelstahl GmbH
Stefan Beck
Buderusstraße 25
35576 Wetzlar
Germany
Phone: +49 6441 374 - 0
Fax:
+49 6441 374 - 4571
E-mail: [email protected]
AEO-F
ISO 9001
ISO 14001
ISO/TS 16949
ISO 50001
Legal notice:
Buderus Edelstahl GmbH has taken the greatest care in compiling this information. It is nevertheless possible that details
may have changed in the meantime. Please appreciate that
we are therefore unable to guarantee the accuracy and completeness of the information provided. We reserve the right
to make changes to the content at any time. Please also note
that we accept no liability for obvious printing errors and
mistakes. All details, information and descriptions are
non-binding and only become binding as part of a contract to
be concluded separately.
©
Buderus Edelstahl GmbH, Wetzlar, 04/2015