ALLUCAN AG—Expertise in aluminum welding

Comprehensive service and innovative production

ALLUCAN AG offers a 360° service—from consultancy, design, and mechanical processing right to final production. Thanks to flexible manufacturing technologies, the company can produce prototypes quickly and efficiently, while automated processes facilitate the production of higher quantities with consistent quality. Individual customer requirements are transformed into customized solutions with the help of detailed analyses.

Certified quality and innovative strength

The combination of technological excellence, strict quality standards, and an experienced team makes ALLUCAN AG a dependable partner. The Swiss aluminum experts are committed to the highest quality standards, underlined by certificates in accordance with ISO 9001:2015, DIN EN ISO 3834, DIN EN 1090, DIN EN 15085, and DIN 2303, as well as DNV Workshop Approval. The know-how and experience of the workforce have been key success factors for many years. In the locomotive vehicle construction sector in particular, ALLUCAN AG has developed a number of innovative solutions tailored to specific industry requirements. 

Feasibility studies and quality controls

Before new components go into production, ALLUCAN AG conducts comprehensive feasibility studies. First, the design drawings are checked in close collaboration with the customer and adapted if necessary, until the ideal welding conditions for the welding sequence and the layer build-up are guaranteed. During the subsequent process and work sample tests, a range of test methods are used to ensure the quality of the weld seams, including visual inspection, dye penetration, ultrasonic and X-ray tests, all of which are carefully documented to prove compliance with the standards. These tests are further complemented by technological material tests and the production of micro and macrosections.

Once the feasibility tests are complete, the company produces both painted and unpainted component samples for First Article Inspection (FAI) by the customer. Series production can only commence once the customer has given their approval on site at the Bremgarten plant. Before finished components are ready for picking, they undergo a detailed final inspection, which includes a digital 3D measurement using a special mobile camera to check for possible dimensional deviations and distortions. The end products are only delivered once all tolerances satisfy the customer’s requirements.

Transformer enclosures and special housings for electric locomotives

ALLUCAN AG manufactures lightweight transformer enclosures and special housings from aluminum, which are primarily used in high-performance locomotives and high-speed trains. Such aluminum housings increase the energy efficiency of locomotives, while also complying with strict safety requirements. This demands precisely placed welds with consistent geometries and layer build-ups. Up to 20 or more weld layers have to be produced, depending on the material thickness.

Welding often takes place using the TIG welding process, which brings several advantages. For example, TIG enables the welder to produce flawless, flat welds, which guarantee an optimum basis for the subsequent layer build-up, while the smooth TIG beads minimize the risk of notch effects, which enhances the structural integrity of the welded joints.

MIG welding—which is particularly suitable for thicker materials—is used to build up the layers. It allows high welding speeds and offers good control over the weld. This is where the iWave AC/DC Pro 500i multiprocess welding machine excels, guaranteeing welding quality without compromise for every single weld. One particular advantage of this welding machine is the rapid and straightforward changeover from TIG to MIG and vice versa.

CEO Markus Jäger highlights the advantages of the iWave welding system: “Thanks to Fronius, we can switch flexibly between the different welding processes at the touch of a button. This flexibility—in particular the savings in working time and space requirements—is greatly beneficial to us. All Fronius welding machines stand out due their exceptional service life and stability, and especially noteworthy is the availability of spare parts for many years, which ensures that we can continue to rely on the devices in the long term. That’s why they are so popular with us.”