Development of an optimized surface preparation process, soldering station and technology, as well as a test procedure for soldered joints with increased reliability.
Surface preparation is particularly emphasized in soldering technology because the base material and the solder material do not form a common molten pool. Consequently, the surface quality and cleanliness of the parts to be soldered have a significant impact on the spread of the solder and the wetting conditions. From a technical perspective, a key result here is the clear definition of a surface preparation process that takes into account the characteristics of contamination deposited on the surface during pre-manufacturing technologies, the capabilities of the washing process, and the contamination-removing effect of the flux.
The results related to the process include the installed and optimally matched system elements, as well as the manufacturing process descriptions and documentation describing them. As a result of the project, soldering stations designed for the specific parts will be produced, which ensure adequate quality through an improved process monitoring and control system.
The heat source used in the soldering station and its characteristics (type, quantity, positions, directions, heating times, etc.) are designed based on the knowledge acquired during research, similar to the process monitoring or control system. Thus, a complex system is assembled that can implement soldered joints with a lower ppm than the current scrap rate.
The result covers the manufacturing documentation of the systems and processes, as well as the joint testing documents, which verify the effectiveness of the development. Improving the compliance of joints will be achieved through the combined effect of surface preparation, the improved soldering process, and the enhanced testing procedure.
From the joint testing side, the completeness of new testing tools and processes is determined based on the knowledge acquired during research. This includes the equipment and associated building elements (fixtures, clamps, storage units, etc.) and the sequence of the steps applied.
As a result of the project, an aluminum soldering technology has been created through which we can reduce the scrap rate during the production of parts made of aluminum, and the number of failures during the lifespan of vehicles will also decrease.
The project was implemented within the framework of the Széchenyi Plan program.
The aim of this project was to expand our production capacity, as our current capacities were utilized at nearly 100%, making the acquisition of new production equipment necessary to fulfill new orders.
Within the framework of the project, production equipment and related material handling devices necessary for the manufacture of 16 different components and 2.4 million cooling water pipes per year were procured. A significant portion of the cooling water pipes produced are installed at the Audi plant in Győr, while a smaller portion is used at the Porsche engine plant in Stuttgart.
The following acquisitions were realized under the project:
