Metal processing

Precision in every dimension:

With our high-performance machinery, we process complex and large-format components weighing up to 130 tons – including turning, milling, honing, cladding and hardfacing. Whether welded constructions, maritime steel construction or repair welding: we deliver the highest quality from a single source. A special highlight – our mobile processing directly at your site.

Machining

Our company covers a very broad spectrum of machining processes – from the smallest precision parts to large components weighing several tons (up to approx. 130 t ). State-of-the-art CNC lathes and portal milling centers enable high-precision machining of even very large or long workpieces (e.g. shafts up to 12.5 m long). Special processes such as honing extremely long bores (up to 7 m) are also available in order to machine internal surfaces with maximum precision.

Welding technology

Our welding department repairs worn or damaged machine parts by repair welding and protects surfaces by build-up welding (cladding/armoring) with wear-resistant or corrosion-resistant coatings. Innovative high-performance processes such as UP ICE® welding are also used to hardface even large components with minimal heat input. Experienced welding specialists and quality assurance certified to international standards (including ISO 9001) guarantee the highest quality and reliability in all production steps.

Our range of services
up to 130 t unit weight

Conventional turning up to 12,500 mm

Heyligenstaedt/VDF
Center width: 12,500 mm – Ø 900 mm
Weiler DA260
Center distance: 2,000 mm – Ø 535 mm

Cycle-controlled turning

Hamlet E110 (1)
Center distance: 9,000 mm – Ø 1,100 mm
Hamlet E110 (2)
Center width: 3,000 mm – Ø 1,100 mm
Hamlet E70
Center distance: 3,000 mm – Ø 500 mm
Hamlet E50 (1)
Center distance: 2,000 mm – Ø 300 mm
Hamlet E50 (2)
Center width: 1,000 mm – Ø 300 mm
Hamlet DZ67
Travel distances: Longitudinal travel (z) = 600mm
Plan path (x) 250mm

Milling center SHW UniForce 8

  • max. table load: 130t
  • Travel paths:
    • x= 12.000mm
    • y= 6.500mm
    • z= 1.900mm
    • w= 2.500mm
  • Head change system
  • Interpolation turning
  • Movable positioning table

SHW Powerspeed 5 turning and milling center

  • Turntable: Ø 1,600mm
  • max. possible turning operation: Ø 1,800mm
  • Max. table load for turning operations: 3t
  • Max. table load for milling: 6t
  • Travel paths:
    • x= 6.000mm
    • y= 2.100mm
    • z= 1.300mm
  • Automatic universal milling head

SHW UniSpeed 7 milling center

  • Clamping surface of the table: 6,000×1,300mm
  • max. table load: 19t
  • Travel paths:
    • x= 6.000mm
    • y= 1.600mm
    • z= 1.300mm
  • Positioning tables: 2
  • Axles: 5

Bed milling machine MTE/K25

  • Clamping surface of the table: 2,700x850mm
  • max. table load: 6t
  • Travel paths:
    • x= 2.500mm
    • y= 1.000mm
    • z= 1.100mm

Honing benches

Sunnen HL-3500
Machining length: up to 7000 mm – Ø 480 mm
Honing GOE-2000
Machining length: up to 4000 mm – Ø 480 mm on envelope

Boring mills

Collet 175
Machining: 4,500 x 3,100 mm
Depth: 1,500 mm
maximum weight: 100,000 kg

Repair welding is a cost-effective way of restoring the serviceability of defective machine parts.

Crack, fracture, wear or corrosion damage is permanently repaired by welding, spraying or soldering. The particular strength of Druckguss Service Deutschland GmbH lies in the processing of difficult-to-weld materials such as heat-treatable steels, tool steels, casting materials (spheroidal graphite iron, lamellar cast iron) and complex material combinations.

A comprehensive range of machinery, including automatic internal and external circumferential welding machines, is available.

Examples of applications include worn shafts, defective bearing seats, corroded bores (diameter 50-500 mm), worn drive shafts and broken guide pillars on presses or die casting systems (up to 8,000 mm long).

Mobile repairs are also possible in combination with mobile processing.

Hardfacing (increasing the wear resistance) or cladding (increasing the chemical resistance) make it possible to refine an inexpensive base material.

We find applications in containers, valves, earth-moving machines and clamping plates.

The clamping plates of die-casting machines are given a coating that significantly increases both the chemical and mechanical resistance.

Our welding department plans, manufactures and monitors the production of all types of welded constructions.
High-quality clamping devices, modern inverter welding power sources and our excellently trained staff are the basis for the high quality of the constructions we produce.

We can manufacture steel constructions that fall within the scope of building inspections up to EXC 3 in accordance with EN 1090 (dynamically stressed welded constructions). We are also certified in accordance with DIBt z-30.3-6 for steel structures made of stainless steels.

An in-house international welding engineer and an international welding specialist ensure quality assurance in accordance with ISO 3834-2 and ISO 9001:2015.

Sheet metal and rolled metal processing, restamping approvals and DNV GL and Bureau Veritas approvals round off the manufacturing options.

Downstream mechanical processing is ensured with our production facilities on over 11,000 m2 of production space.

Welded constructions in the maritime sector require particularly high production quality from the manufacturing companies.

Druckguss Service Deutschland GmbH has all the facilities and personnel resources available to produce high-quality maritime steel constructions (e.g. rudder cokers, rudder blades, ship add-on parts, etc.)

Our own inspectors (in accordance with DGZfP) carry out the testing of these components using the VT, MT, PT, UT methods.

If independent testing is required, we have high-performance partners in the neighborhood.

ESAB UP ICE® high-performance welding system

How it works
The patented UP-ICE® process is based on 3-wire technology, in which an arc is formed on two hot wires. A third wire (cold wire) is added in the middle of the two hot wires. By feeding a cold wire into the weld pool created by the hot wires, a significant deposition rate can be achieved without increasing the heat input. The mixing ratio in the weld metal is always a factor that must be taken into account in submerged arc processes.

With the UP-ICE process, we can achieve mixing ratios that are lower than those of less powerful MAG processes. This enables us to clad heavy weldable materials such as gray cast iron.

Advantages of this procedure

  • Very high melting capacity
  • Low mixing / low heat input
  • Welding of heavy weldable materials possible
  • High process stability
  • Error-free and reproducible welding process
  • Weld seam alloy can be customized according to customer requirements

Special technical features

  • Fully automatic welding process
  • Ideally suited for joint welding of butt and fillet welds
  • Perfect for cladding components with high-alloy filler materials
  • Highly productive welding thanks to 3-wire technology
  • Welding with reduced distortion thanks to cold wire feed
  • Work area:
    • Width: 4.500mm
    • Length: 9,000mm
  • Piece processing of up to 130t

Areas of application

  • Joint welding of large panels / components
  • Production of long and flawless weld seams (e.g. on base frames, dynamically loaded frames)
  • Plating of surfaces (application of a corrosion protection layer)
  • Armoring of surfaces (application of a wear protection layer)