Forging and rolling
ZOLLERN offers forged and rolled products made of copper and copper alloys. The preliminary material needed for forging is produced in-house. The high vertical range of manufacture at ZOLLERN guarantees a high quality and short lead times.
Advantage of forging compared to extrusion
- More uniform structure in forging
- Low risk with respect to internal errors
- Fewer internal stresses
- Low warpage after machining forged material
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Forgings made of pure copper and copper alloys
ZOLLERN supplies forged products made of pure copper and copper alloys
Unit weight: up to 4 tonnes
Diameter: 40 - 500 mm
Lengths: 1 - 10 m
Forging often transforms the previously coarse-grained cast structure into a fine-grained structure. This increases the strength values, while the toughness and ductility are maintained. Due to the high level of tightness, the forged parts offer a high level of operational reliability under high pressure loads as well as in vacuum applications.
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Drop forged parts
Depending on the complexity of the geometry, ZOLLERN produces drop forging parts weighing up to 15 kg.
Due to the near-net-shape moulding, the amount of material used is reduced and the subsequent machining is reduced to a minimum or can be completely done away with.
Drop forging is characterized by a high degree of repeatability and is especially well-suited for large and medium quantities.
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Rings, seamlessly rolled
ZOLLERN offers rings with a unit weight of up to 250 kg and an outer diameter of 2,500 millimetres.
Features and advantages:
- Very good kneading
- Near-net-shape surfaces
- Also suitable for smaller quantities
- Short delivery times
- Seamlessly rolled and forged copper rings
- Produced in a modern ring-rolling mill
- First-class surface quality
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Individual pieces, small series, large series
ZOLLERN produces rings, flat bars and shafts as individual parts, in small series up to large series.
We cover all processes in-house – from melting the alloy, the forming, with or without heat treatment, and a subsequent optional machining and quality assurance.
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Component solutions for the aerospace industry
ZOLLERN provides advanced component solutions made from copper materials for the aerospace industry. All manufacturing processes are realised in the plant – from melting the raw material and casting through to the finished component ready for installation after non-destructive or destructive testing. Production occurs according to the standards AMS 4881, AMS 4880, AMS 4640, BSB23, UZ19A6.
ZOLLERN semi-finished products for aerospace
- Round bars, forged
- Bars, pressed, drawn
- Bushings, centrifuged, to 500 mm length
Applications
- Landing flaps, landing gear
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Individual component solutions for maritime applications
ZOLLERN steel alloys and bronze alloys for marine and offshore applications
- Hub housing and propeller blades for marine propulsion systems
- Sliding blocks
- Fittings and valve housing
- Round bars, flat bars, rings
Offshore applications of ZOLLERN forged and cast bronzes
- High-strength and seawater-resistant bushings and washers for jack-up systems on oil production platforms
- Propellers for drives for positioning drilling platforms in deep-sea oil production
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Component solutions for industrial engines and traction motors
- Short-circuit rings, slip rings, short-circuit rods; for larger rotors
- Cap rings made from high-stability copper alloys; for fast-running rotors
- Seamlessly rolled and forged rings in pure copper
- Slip rings
- Rings with external diameters from 200 to 1,600 mm
- Rings in pre-processed and fully finished condition
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ZOLLERN forged bronzes and complete solutions for general mechanical engineering, forming and mould making
ZOLLERN offers individual component solutions from copper-based materials for machines in sheet metal forming and solid forming.
- Spindle nuts
- Bearing bushes
- Thrust bearing, thrust ring, thrust plate
- Flat guide rails, guide shafts
Custom designs
- High-strength copper-aluminium alloys forged, rolled
- Copper alloys centrifuged or cast in sand
- Mechanically pre-machined or finish machined
- Quality-checked, with factory certificate
- Maximum component quality, very good gliding behaviour, high wear resistance, fatigue endurable
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Copper and copper alloys for cooling technology
The high thermal conductivity of pure copper and low-alloyed copper alloys, such as CuCr1Zr and CuNi3Si, is used for heat sinks in different application areas:
- Dies in continuous casting and wire rod plants
- Components for welding systems
- Parts for accelerators in research and medicine
- Rocket nozzles
- Heat exchanger
- Cooling plates, heat sinks in general, also in high-vacuum areas in research facilities
Copper-aluminium alloys, among others, are used for a higher wear resistance, for example in injection tools where the thermal conductivity of steel is insufficient.
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Alloys, standards, specifications
ZOLLERN supplies forged parts, rolled components and rings made of copper and copper alloys according to national and international standards, as well as according to customer-specific standards:
- DIN
- EN
- ASME
- ASTM
- AMS
- AD2000
- NSMT
- French or British standards
- Customer-specific requirements with increased strength values or other quality characteristics are possible by request
Alloy groups
- Copper-aluminium
- Copper-zinc
- Copper-chrome-zirconium
- Copper-nickel
- Copper-nickel-silicon
- Pure copper
- Special alloys with a copper basis