At the present time the company ŽOS Vrútky Jsc. pays a big attention to welding technics as well as verification of technologies due to continuous increasing of welding importance in rail vehicles production as well as repairing and refurbishing technologies.

CUTTING OF MATERIAL

LASER

The laser cutting machines allows to work with high-tech procedure in 2D system with high speed, accuracy and quality of cutting with very small temperature influence to material without need of further mechanical machining.

Source – Trulaser L 3040 3200W power

Main applications:

Working surface: 2000 x 4000 mm

• cutting of thin sheets made of high-alloy steels: max. thickness 12 mm
• cutting of sheets made of common structural materials: max. thickness 20 mm
• cutting of sheets made of aluminium and its alloys: max. thickness 8 mm

Used gases

Laser gas

• CO2 4.5
• N2 5.0
• He 4.5

Cutting gas

• O2 beam (GOX 3.5)
• N2 5.0 beam (GAN 5.0)

PLASMA

Microstep CNC plasma cutting machine allows to work with HIFOCUS 100 cutting equipment with procedure in 2D system with sufficient speed, accuracy and quality of cutting for parts of larger dimensions and of bigger thicknesses.

Source – Kjellberg Microstep CNC PL 7501.20 + HiFocus 100

Main applications:

Working surface: 2000 x 7500 mm

• cutting of thin sheets made of high-alloy steels: max. thickness 20 mm
• cutting of sheets made of common structural materials: max. thickness 30 mm
• cutting of sheets made of aluminium and its alloys: max. thickness 20 mm

Used gases

Cutting gas

• H2 4.5
• Ar 4.6
• N2 / H2 4.6
• O2 3.5
• N2 5.0
• compressed air

WELDING

Method of resistance spot welding

Sources:

TECNA 3307N hanging pointing pliers

Parameters:

max. welding power: 108 kVA

max. thickness of welded sheet made of structural steels in case of arm lenghts:

• L= 250 mm: 5 + 5 mm
• L= 508 mm: 3,5 + 3,5 mm
• L= 1030 mm: 2 + 2 mm

TECNA 6250N stationary pointing pliers

Parameters:

max. welding power: 1000 kVA

max. thickness of welded sheet in case of arm lenghts:

• L = 800 mm - structural steels 4 + 4 mm
• CrNi steels 3 + 3mm
• aluminium and its alloys 3 + 3mm
• wires, plain steel Ø 12,5 + Ø 12,5 mm

Method of MIG/MAG/TIG arc welding

For mentioned method a series of Kemppi welding sources is used:

• Kemppi Pro system 4000W
• Kempomat 3200
• Kemppi Pro Evolution 4200
• Fastmig 400 Synergic
• WeldForce 3500
• Kempact MIG
• MasterTig AC/DC 3500 W

Main applications:

• semi-automatic machine welding of long welds by BUG-o and Kjellberg Microstep CNC 7501 system
• welding of thin sheets made of high-alloy steels
• welding of common and alloyed structural materials
• welding of copper, aluminium and its alloys
• renovation welding works (machine building-up welding in the special positioners)

Used gaseous shield:

• Ar 99,999%
• Ar 95% He 5%
• Ar 82% CO2 18%
• Ar 97% O2 3%
• CO2 100%

Method of high productive arc welding and submerged building-up welding

Source – building-up welding machine VÚZ NAKO 1 tandem

Applications:

• building-up welding of all types of wheel sets of the rail vehicles,
• building-up welding of journals,
• building-up welding of labyrinths

MMA method of arc welding

Sources - Minarc 150, WeldForce 3500, Kemppi Pro Evolution 4200, Fastmig 400 Synergic

Applications:

• special repairs of cast-iron parts
• welding of common structural parts

Preparation of material before welding

A big attention is paid to preparation of material before welding due to adherence to accuracy and quality of welded parts as well as accurately cutting of material:

Sources:

• Press brakes with CNC control
• Profile bending machines, tube bending machines with CNC control
• Rounding machines of sheets with the possibility of conical surfaces rounding
• Chamfering machines for edge chamfering

Company´s development and strategy

At the present time the company introduces the robotization into the production of weldments due to reason of competitiveness. It is used in welding of frames of new passenger coaches as well as parts of weldments occuring in the production of wagons by robotized workplace. Moreover there is other project in progress – the project for high speed spot resistance welding equipment of larger parts with SM Calvörde and JESVA CZ companies – producers of special machines.

Others

The company ŽOS Vrútky Jsc. owns the certificate from TÜV SÜD Industrie Servise GmbH München in compliance with DIN EN 15085-2: C1 standard for performing of welding works in the production of new rail vehicles, furthermore it owns the Certificate for welding process according to ČSN EN ISO 3834-2 from SVV Prague, Permission for welding of track vehicles, repairs and reconstructions of pressure vessels of track vehicles by welding from ÚRŽD Bratislava EN 15 085-2 CL1.