Zetwerk For Manufacturing Expertise

FORGING

Zetwerk’s proven experience in forging serves some of the most operationally demanding manufacturing requirements. With cutting-edge design tools, software and a global network of skilled partners, Zetwerk produces high quality forged components, progressing from prototypes in open die forging to hardened steel closed die mass production, resulting in shorter lead times.

METHODS

Zetwerk uses industry-leading die casting methods like High Pressure Die Casting (HPDC), Low Pressure Die Casting (LPDC) and Gravity Die Casting (GDC), with capacity ranging from 80T to 3500T. Shaped in a variety of metal alloys like aluminum, zinc, copper, brass and bronze alloys, die cast components are formed in precision steel tools, moulds and dies as per volume, size, weight, geometry, complexity and surface finish requirements.

MATERIAL AND WEIGHTS

Open Die Forging

Zetwerk utilizes open die forging to hammer into shape parts as large as 150T and 25 metres in weight and height respectively. This process allows for open die forging of all forgeable ferrous and non-ferrous alloys,including exotic materials like age-hardening superalloys and corrosion-resistant refractory alloys.

Closed Die Forging

For complex shapes and tighter tolerances, Zetwerk employs closed die forging using two or more dies containing impressions of the part shape. Engineering metals and alloys like carbon and alloy steels, tool steels, stainless, aluminum and copper alloys and titanium alloys can be forged through closed die forging.

Cold Forging

While most forging is done as hot work, Zetwerk is also proficient in cold forging processes like bending, cold drawing, cold heading, coining and extrusions to create a diverse range of part shapes. The output is forged parts that have enhanced dimensional control, product uniformity and surface finish.

Rolled Ring Forging

Zetwerk performs rolled ring forging by punching a hole in a thick, round piece of metal, and then rolling and squeezing the metal into a thin ring. Ring diameters vary from less than a meter to over 10 meter

FINISHING TOUCHES

Zetwerk offers necessary secondary operations on the forged parts such as finish machining, heat treatment and surface treatment. Its quality-driven process ensures that the forged parts meet exact specifications of material chemistry, dimensional accuracy, mechanical properties, and structural integrity. Forging heat treatment services include normalizing, annealing, quenching, tempering, stress relieving, spheroidize annealing, solution annealing, solution heat treating and straightening. Zetwerk also provides a host of mechanical, metallurgical and non-destructive testing services to make sure that the produced parts meet quality standards.

QUALITY CONTROL AND ASSEMBLY

Zetwerk’s Quality Control includes testing and heat treatment of cast components. Salt Spray tests and Hydrostatic and Pneumatic pressure tests determine the corrosion resistance of the die casting. For ease of assembly, Zetwerk also offers the produced parts in a sub-assembly along with hardware and other components necessary for assembly.