Closed die forgings FOR THE COMMERCIAL VEHICLE INDUSTRY, MINING, THE OIL AND GAS INDUSTRY, GENERAL MECHANICAL ENGINEERING AND AGRICULTURAL MACHINERY

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1 Closed die forgings FOR THE COMMERCIAL VEHICLE INDUSTRY, MINING, THE OIL AND GAS INDUSTRY, GENERAL MECHANICAL ENGINEERING AND AGRICULTURAL MACHINERY

2 Buderus Edelstahl Buderus Edelstahl CONTENTS Buderus Edelstahl 2 Products 4 Production 5 Quality 7 CLOSED DIE FORGINGS FOR HIGH DEMANDS BUDERUS EDELSTAHL QUALITY FROM A SINGLE SOURCE: The entire production process, from melting through to production 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. 2 3

3 Products Production PROGRESS THROUGH QUALITY QUALITY STARTS EARLY ON Our closed die forging plant plans and produces drive and axle components for the commercial vehicle industry, as well as complex 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 mechanical properties adapted precisely to the relevant use high degree of process reliability during production stable quality features and part traceability over many years complete dimensional accuracy in accordance with drawing specifications just-in-time deliveries 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. CLOSE TO THE CUSTOMER FROM 2 TO 220 KG 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. Throughout the development process, our employees from the fields of technology, product management and sales are in constant 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. We produce closed die forgings on six press lines with compression 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. Induction heating plants heat up the sawn billet sections to forging 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 are process-monitored and computer-controlled. Some of the machines are fully automated and equipped with robot technology. 4 5

4 Production Quality MODERN SYSTEM TECHNOLOGY CERTIFIED TESTING 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 OUR PRODUCTION PROCESS 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. 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 and ISO 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 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. 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 6 7

5 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 AEO-F ISO 9001 ISO ISO/TS ISO Buderus Edelstahl GmbH Stefan Beck Buderusstraße Wetzlar Germany Phone: Fax: closed-die-forge@buderus-steel.com 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