Vacuum investment casting

Ground tapping method
Highly productive melting and casting process for complex components made of highly heat-resistant materials. Large quantities can also be produced in a short period of time with a very high level of reproducibility.

  • From individual parts to large series
  • High degree of purity
  • Possibility of targeted grain refinement on the castings
  • High degree of automation

Tilting crucible method
Melting and casting process for the production of complex components made of high-temperature resistant materials with a high purity and very good reproducibility.

  • From individual parts to large series
  • Very high degree of purity
  • High degree of automation in production, autonomous casting by casting cell (pre-heating to cooling)

Open air investment casting

Conventional method

The conventional open investment casting - is a lost wax process that is characterised by an almost unlimited selection of alloys.

  • Component weight up to 100 kg
  • Manual pouring off of the casting cluster in an oxygenated environment
  • The mould is filled manually via a ladle and is controlled by the casting speed
  • Maximum installation space 600 x 600 x 550 mm

Roll-over technology

A very high material quality is achieved with roll-over technology. After melting the alloy, the furnace rotates 180 degrees in a few seconds. The mould shell that is flanged directly to the furnace is filled precisely and with low turbulence in the process, also while using inert gas.

  • The influence of oxygen is eliminated by using an inert gas bell.
  • The maximum installation space is 580 x 400 mm diameter
  • Maximum casting weight of 100 kg

Sand casting

The sand casting process offers a high degree of freedom and the economic production of complex components with undercuts and cavities

  • For individual parts and small series
  • Production according to the permanent model, lost model or based on printed/milled moulded parts
  • Part weights: Copper alloys up to 8,000 kg, steel alloys up to 2,500 kg
  • Production using a lost mould

Croning casting / shell casting

Complex components with cavities and a high surface quality can be economically produced with Croning casting or shell casting.

  • Surface quality Ra 6.3 µm
  • Large series
  • Metallic models
  • Weight range up to about 20 kg
  • Part dimensions up to about 400 x 250 x 200 mm
  • Production using a lost mould

Ceramic casting

Ceramic casting is particularly well-suited for thin-walled components and high degrees of purity when casting special materials

  • Non-reactive moulding material
  • suitable for cores and moulds
  • Part dimensions 1400 x 1400 x 600 mm
  • Production using a lost mould

Continuous casting

Round solid material is economically produced from copper alloys in the continuous casting process

  • Diameter 120 to 620 mm
  • Length up to 2,400 mm
  • Production using a permanent mould

Centrifugal casting

The centrifugal casting process is particularly well-suited for the economic production of rotationally-symmetrical bushings

  • Diameter up to 400 mm
  • Length up to 500 mm
  • Production using a permanent mould

Direct Contact

P +49 (0) 7571 70 370

Forged parts

Open die forging

ZOLLERN produces round and square workpieces, from shafts to flat bars, with several pneumatic hammers and a 1,600 tonne hydraulic forging press.

Dimensions of the workpieces
40 - 500 mm
Lengths: 1 - 10 m

Ring rolling

In ring rolling, an ingot blank is placed on the forging press and rolled onto the ring rolling mill.

Dimensions and weight of the seamlessly rolled rings
up to 2,500 mm
Unit weight: up to 250 kg

Drop forging

Drop forging or stamping are particularly well-suited for the production of larger quantities.

Weight of the forged parts
Unit weights:
up to 15 kg

Process chain

ZOLLERN offers a high vertical range of manufacture for efficient processes and first-class quality.

  • Primary forming
  • Forming
  • Separating
  • Changing substance properties
  • Casting
  • Forging/rolling
  • Cutting machining
  • Solution annealing and tempering
  • Quality assurance in in-house laboratory

Direct Contact

P +49 (0) 7571 70 370

Special profiles and finished parts

Hot rolling

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences

Heat treatment

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences.

Cold drawing

With cold drawing, the pre-formed hot rolled profile is drawn one or multiple times by a carbide die and brought into the desired shape. Stress introduced is neutralised between the forming steps via heat treatment.

Cold rolling

With cold rolling, a wire rod is brought into the specified final contour at room temperature by rolling. Several rolling units in a production line automatically perform this process and give the profiles a high surface quality. The process is particularly well-suited for manufacturing small profile geometries, which are needed in larger quantities.

Inductive hardening

ZOLLERN uses inductive hardening to increase the wear resistance of the profile surfaces. Hardening depths of 0.5 to 5 millimetres and hardness values of up to 64 HRC are achieved.

Direct Contact

P +49 (0) 7571 70-380