Thompson produces machine for world's largest auto axle maker

A Thompson friction welding machine capable of producing more than 150,000 truck axles a year has been installed at the world's largest automotive axle maker in China.

Thompson, the Halesowen-based manufacturer, has also used the world's strongest industrial robot, a KUKA Titan, for the automated component loading/unloading operation at Fuwa's factory in Guangdong Province.

The heavy-duty robot undertakes a series of tasks using a specially-designed, dual-purpose end effector, which means it can hold a trio of unwelded parts at the same time as it unloads a 160kg welded axle assembly from the machine.

After loading the set of components to be welded in to the system, the robot places the finished assembly on to an output conveyor before returning to the input conveyor to pick up its next batch of parts.

Fuwa's Vipan Bhalla said Thompson had been chosen for the project because of the superior build quality, performance and reliability of its truck axle friction welding machines.

Thompson produced the machine in a double-ended design so that two welds can be performed simultaneously to join the fabricated steel banjo to a pair of turned spindles.

Other special features of the machine include a centring bung, a special device for securing the components in position so that tight tolerances can be achieved, as well as a shear flash removal tool.

"This is one of our largest automation projects to date and represents the first time that we have integrated such a heavyweight robot model with a friction welding system," explained Nick Edge, Thompson's global sales manager.

NEW MANAGER FOR SUB-CONTRACT WELDING FACILITY

Friction welding machine manufacturer Thompson has appointed a new manager to head up its sub-contract friction welding service and expanded the operation by adding a new machine.

Jayne Shimwell, who has worked in Thompson's sub-contract department for 15 years, works with a 10-strong team at the Midlands-based facility, which is believed to be the largest of its kind in Europe.

The new 150 tonne friction welding machine, built by Thompson's engineering team at its headquarters in Halesowen, features new environment-friendly, low power consumption drives and a new linear track system for more streamlined operation of the weld head unit. It is designed for joining components such as axles, piston rods and drill pipes.

This new technology, together with the inclusion of special forge clamps and an extended back stop facility, is designed to further improve weld quality and finishing of parts, said Jayne.

"More businesses are using our sub-contract facility not only for friction welding components for small, medium or large production runs, but also for development and research purposes," she added.

The new equipment brings the total number of friction welding machines in the facility to 12. The machines are capable of welding a huge range of components in varying diameters and lengths and in a variety of dissimilar materials such as stainless steel to carbon steel and copper to aluminium.

Thompson's investment in its sub-contract facility coincides with a boom in orders for its friction welding machines, which are in high demand from many sectors including the oil and gas exploration industry.

Thompson has also unveiled the first model in a new range of linear friction welding systems that are designed for use in the aerospace and power generation industries.

Further details on Thompson's sub-contract friction welding services are available online at www.thompsonfw.co.uk or email sales@thompsonfw.co.uk.


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LINEAR FRICTION WELDING SOLUTION FOR JOINING AERO PARTS

Thompson will showcase its linear friction welding solution for producing a range of titanium aero components at a fraction of the cost of other traditional manufacturing methods on stand B10, Hall 4, at theFarnborough International Air Show.

The award-winning machine manufacturer says the linear process can be used to make tailored blanks, which eliminate the need for vast amounts of raw material usually associated with machining components from solid billets.

Thompson says these pre-formed components offer typical savings of 70 per cent and adds that its work with some of the world's top aircraft makers has already identified a number of parts that show potential multi-million dollar savings in material.

Its new E100 machine is specially designed to use the linear friction welding process to join one or more parts together to create larger structures and prismatic shapes. The method produces a solid phase bond with near parent metal properties.

Tailored blanks offer an attractive alternative to machining as many aircraft components have complex shapes such as stringers, flanges and webs added to their basic construction, explained Nick Edge, Thompson's global sales manager.

"In order to arrive at the net finished shape, a significant amount of raw material has to be removed during the machining process and this results in high buy-to-fly ratios of 10:1. Using the linear method means buy-to-fly ratios can be as low as 2:1," he added.

While other technologies such as laser welding and metal deposition remain in the very early stages of development, linear friction welding is an established process that has been successfully used for more than two decades by jet engine makers to produce safety-critical components such as blisks, said Nick.

"The continuing growth in raw material prices and the wider use of difficult-to-machine materials such as titanium alloys means the application of linear friction welding can make a major contribution to lowering production costs."

Thompson's E100 is the first in a series of linear friction welding machines for aerospace applications and complements the Halesowen-based company's range of rotary friction welding machines which are used to produce parts for the automotive, construction machine and mineral exploration industries.

Linear friction welding involves rubbing two pieces of material together while applying a load to produce frictional heat. It can be used to join similar/dissimilar materials in almost any shape from rings and blades to fans and square metal contactors.

Further information on Thompson's E100 linear friction welding machine can be viewed online atwww.linearfrictionwelding.com or emailsales@linearfrictionwelding.com.

Thompson will share its stand at Farnborough with sister company, KUKA Automation + Robotics, who will be demonstrating its latest robotic end effector solutions for aerospace applications.

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PRIME MINISTER IS FULL OF PRAISE FOR MIDLANDS ENGINEERING FIRM

Prime Minister Gordon Brown has praised a Midlands engineering company for putting “British manufacturing on the map” during a visit to its Halesowen headquarters.

He congratulated Thompson, the award-winning manufacturer of friction welding machines, on its export sales achievements and commended its innovation and investment in apprenticeships.

The Prime Minister, who was accompanied by Business Secretary Lord Mandelson and Halesowen MP Sylvia Heal, was shown one of the company’s latest friction welding machines, which is being built for a Chinese automotive axle manufacturer.

Mr Brown also took questions from Thompson employees on a range of issues as he visited the region ahead of the final leaders’ debate at Birmingham University.

“I want to congratulate you on coming through a difficult economic period, for the great technological skills you are developing, for putting British manufacturing on the map in every continent of the world and for hiring apprentices even in difficult times,” he told staff.

The Labour leader also praised Thompson for achieving a Queen’s Award for Enterprise, which recognised the company’s remarkable export sales record in the last three years.

Alan Shilton, Thompson’s managing director, said he was delighted to welcome the Prime Minister to the factory and provide an insight into how a Black Country business was flying the flag for British industry.

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WORLD'S OLDEST DRILL PIPE MACHINE STILL GOING STRONG AFTER 40 YEARS

WORLD'S OLDEST DRILL PIPE MACHINE STILL GOING STRONG AFTER 40 YEARS

Thompson is celebrating a remarkable engineering milestone after learning one of its first friction welding machines for producing oil drill pipes is still in use more than 40 years after it was made in the Midlands.

The Halesowen-based firm believes it is the oldest working machine of its type anywhere in the world and is delighted by the discovery, which only came to light when the Indian drill pipe manufacturer Oil Country Tubular ordered a new friction welder for its factory in Hyderabad.

The company plans to continue using its existing Thompson machine, but now needs the additional equipment to boost productivity as a result of the global boom in oil and mineral exploration.

"The longevity of this machine is a tremendous acknowledgement of the engineering skills and quality of workmanship that are still the hallmarks of Thompson friction welding machines today," commented Simon Jones, Thompson's Asia sales manager.

Thompson machines are specially engineered to produce drill rods or heavy-duty oil pipes as they feature extended back stops and special forge clamps for friction welding an unlimited range of pipe sizes and lengths, he explained.

As part of a crop of repeat orders, Thompson has supplied its third friction welder to a Korean manufacturer of drive axles. The company still operates its existing machines purchased 30 and 14 years ago respectively.

Sales of Thompson friction welding machines for producing a wide variety of axles are still flourishing with strong demand from commercial vehicle makers in Europe and the Far East, stated Simon Jones.

Further details on Thompson's rotary and linear friction welding machines can be obtained online at www.thompsonfw.co.uk or email sales@thompsonfw.co.uk. Alternatively, call the sales team on 0121 585 0888.


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