The Best Solution
for your project
Our Process for Manufacturing Components
After our experienced engineers come up with the best solution for your project, we put our team of highly skilled engineers to work.
Smelting to Steel Making
With over 1500 variations of steel recipes, our metallurgists work closely with our steel mill plant to ensure we create the perfect recipe unique to our clients requirements. All our steels are made in small runs as required. The following video demonstrates our steel making process from start to finish:
Forging is our only choice in our component production. Forged steel gives the highest crack and impact resistance. Many OEM’s will try to convince their clients that casting is just as good as forging, we disagree. Casting is cheaper and often hide hidden defects below the surface (cracks, porosity and sand inclusions) that would be exposed as defects in a forged billet. When a steel billet is created it is rolled or forged, improving its structure. The following video explains our forging process:
Testing at Foundry
Depending on the end use of the forging we perform manual, pulse-echo, and/or ultrasonic testing of forgings. Mechanized scanning techniques, such as immersion testing may also be used in certain circumstances. The following video demonstrates our foundry testing methods:
Most OEM’s use castings for components because it is cheaper than forging. We prefer to fabricate our gear casings out forged steel. The individual segments are fabricated to the strictest of welding and inspection procedures. NDT Inspection including 3rd party NATA ultrasonics. Full penetration submerged arc welds on critical joints.
When machining our components we have specialists for proof machining, which then pass it on to our finishing machinists who produce the final component to our strict standards. All our components are dimensionally inspected by our quality control department. All our gears are inspected for final mesh testing. The following video demonstrates our machining process:
Treatments and coatings are chosen by our specialized staff of engineers in the reverse engineering stage of designing the new component. Common Treatments and Coatings include:
- Hard face chrome
- High velocity oxy fluid (HVOF)
- Heat treating
- Stress relieving
- Tungsten coating
- Nickle coating
- powder coating
- Black oxide
Testing for Quality
This machine gives us helix angle’s pressure angles and it pitches all the data we need to make new complex gears that will mesh correctly with mating gear. With the use of this machine we have the capability to make any gear without OEM’s prints. We use many forms of testing on all our components. The following video demonstrates Liquid Penetrant Inspection:
Assembly of Components
We don’t have robots on an assembly line creating your components. Just like a Rolls Royce we create each of our components manually with specialized staff. Every step of the way is checked and checked again. Each project is a work of art.
Testing of Machinery
Our quality control staff have knowledge of the raw materials, production processes and our quality standards. Destructive and non-destructive testing is conducted for checking flaws in the manufacturing process, dimensional issues and ensuring that hidden components are assembled correctly. We ensure that the our component is of high quality, long term reliability and a longer life cycle. Gear boxes are subjected to an 8 hour run test, in our testing facility where it is monitored, calibrated and certified. The following video demonstrates Meshing of Gears:
Shipment of Components
All efforts are made to ensure that your component is properly crated or prepared for its method of travel. We make all the necessary arrangements for pick up and delivery to you. All the paper work is completed by our experienced logistics staff ensuring there are no snags along the way. As our logistics staff say “our gear boxes run like a Rolex and so does the transport”.