Technologies – Wolf Fertigungs- und Fügetechnik

Vacuum brazing metal/metal

Due to the uniform heating of materials and the fully automated processes used in vacuum brazing, we are able to achieve a continuous standard of high quality, especially in components with several joints.

High-temperature brazing in a vacuum is a technique of flux free brazing in a vacuum furnace. Metallic solders are used for metal-to-metal and ceramic-to-metal joints. Particularly in the production of components with several joints and large components, we are able to achieve a continuous standard of high quality by uniformly heating the materials and by using fully automated processes.

There is a wide range of applications for this technology. Vacuum-brazed products are used in the following areas:

Aerospace
Geostationary turbines
Food industry
Refrigeration and air conditioning technology
Vacuum technology
Analytical technology
Plate and tubular heat exchangers
Medical technology
Research and development

This technology has been under continual development for over 25 years. The knowledge we have gained and our expertise in process engineering combine to make Wolf FT a recognised partner in the manufacture of vacuum-brazed components.

Vacuum brazing metal/ceramics

One of the strengths of Wolf FT is ceramic-to-metal bonding using vacuum brazing technology.

Wolf FT not only processes aluminium oxide ceramics, but also sapphires, zirconium oxide ceramics and industrial diamonds.

: Helmholtz Berlin

Our products are widely used in vacuum technology, and aluminium oxide ceramics are frequently used as an insulator in a broad range of structural designs. Wolf FT produces the individual metal components (the ceramic components are purchased from long-standing partners) and carries out further processes such as vacuum brazing, as well as other production steps.

Depending on the design required, we use either active brazing or brazing with metallised ceramics.

Other major areas of use include:

Medical technology
Mechanical engineering
Laser technology
Tool technology

Our company also specialises in micro-brazing processes using a minimal amount of flux for the production of components subject to high thermal stress.

Welding technology

Welding technology is most widely used in the manufacture of composite components and is a key technology in our company, as is vacuum brazing.

TIG welding is generally carried out using semi-automatic machines or welding robots. This enables complex welding solutions to be realised with a high degree of reproducibility and economic efficiency.

Other welding techniques offered by Wolf FT are:

Orbital welding
Stud welding
Resistance welding

Other welding technologies such as laser welding and electron beam welding are implemented in cooperation with expert partner companies.

Mechanical production

We are a supplier to manufacturers of vacuum systems and vacuum components and are specialised in the mechanical processing of stainless steels and aluminium.

Our production facility offers modern machinery in conjunction with a programming system and 3D measurement technology. The components are generally produced in small to mid-sized series.

A turning and milling centre, horizontal and vertical machining centres and diverse CNC lathes for a diameter of up to 500 mm are in operation. We not only process various premium steels and aluminium materials, but also copper materials and nickel-base alloys. Our range of products includes individual parts for welded and brazed constructions as well as complex production parts.

Cleaning – surface technology

Highest demands are placed on the cleanness of manufactured parts and components, particularly in the vacuum industry.

Wolf FT uses a fully automated, single chamber, ultrasonic cleaning system with 3 cleaning baths for cleaning the components. This is a closed system, in which all operations from pre-cleaning to drying are carried out in one fully sealed chamber in an automatic, program-controlled process.

Contaminated parts are perfectly cleaned and dried. The complex process provides not only highest precision cleaning, but also a high throughput capacity.

Other methods of surface cleaning used are:

Belt polishing machine for seal faces
Glass bead blasting
Corundum blasting
Trovalising
Electropolishing in cooperation with external partners
Electroplating in cooperation with external partners

Quality control

Reliability and quality are essential prerequisites for success in any business. Right from the start, Wolf FT demands highest quality standards and produces accordingly, as is demonstrated by the use of modern, computer-aided measurement technology.

3D measuring equipment and surface testing devices are used for dimensional checks and surface inspections in conjunction with standard measuring instruments.

For leak testing, we use helium leak detectors with leak test thresholds as low as 1×10-¹² mbar.l.sec-¹_. Further analyses such as pressure tests and flow-through rate tests assure seamless quality control. Regular monitoring guarantees process safety and machine capability. We also carry out internal audits and external customer audits.

Dimensional inspection:

3D coordinate measuring equipment, measuring range:

X axis: 905 mm
Y axis: 1605 mm
Z axis: 605 m

Leak testing using helium leak detector:

Leak test thresholds down to 1×10-¹² mbar.l.sec-¹_.

Assembly

Wolf FT has a cleanroom (ISO class 6 and 7) of approx. 110 sq m in size, in which components and assemblies are fitted.

In order to guarantee economical assembly, we have equipped fitting trolleys with all the necessary parts and tools for the individual product groups. Our products are assembled by trained personnel in accordance with work instructions.

Subsequently, the assemblies are subjected to function and leak tests depending on requirements. Cleanroom compatible packaging or delivery in special packaging is guaranteed in agreement with the customer.

Production of assemblies

Wolf FT understands its role as a strategic partner in developing complex system solutions and has always emphasised the value of long-term customer relationships. We not only offer advice on production procedures, but provide support right from the start of the development and prototype stages and also manage the purchase of all outsourced components for the assemblies

A cleanroom is available for fitting the assemblies, thus guaranteeing maximum cleanliness. After fitting, the assemblies are subjected to function and leak tests depending on requirements.

Our services also include the packaging of the assemblies in defined containers, or cleanroom compatible double packaging.

Logistic handling of recurring components is generally done on the basis of framework agreements with call-off, Kanban system management or individual orders.

: Helmholtz Berlin

: Vakuumkammer für Max Plank Institut München

: Substrate holder for coating plant

Our machinery

List of machinery and technical description of equipment used.

List of machinery and technical description of equipment used by Wolf Fertigungs- und Fügetechnik GmbH

Vacuum Brazing Equipment

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Vacuum brazing furnace MOV 643 T

Work chamber 600x800x600 mm
Metal-heated
Max. temperature 1200°C
Atmospheres: High vacuum to 1×10^-6 mbar N2 to 150 mbar
Fast cooling: Fan cooling N2
Program controlled

Vacuum brazing furnace MOV 453 T

Work chamber 350x500x350 mm
Metal-heated
Max. temperature 1200°C
Atmospheres: High vacuum to 1×10^-6 mbar Ar to 150 mbar
Fast cooling: Fan cooling Ar
Program controlled

Welding technology

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Welding robot ABB 1

TIG welding robot system
6-axis robot with tilt and turn table
Equipped with torch exchange system for complex welding operations
2 work stations enable tool assignment during the welding process
Welding of stainless steel and aluminium materials
Cold wire feed for additional welds

Welding robot ABB 2

TIG welding robot system
6-axis robot with rotary table
Stainless steel welding

Orbital welding

Stud welding

CNC controlled welding of threaded bolts, internally-threaded bushes, pins, special bolts
Economical and reproducible due to CNC control
Threaded bolts from M3 to M8

Resistance welding

Resistance welding of sheet metal parts
Processing of sheet metal parts up to 4 mm
Microprocessor control (15 welding programmes – 16 programmable parameters for each programme)