Jackweld are poineering surface chemistry modification to enable bonding between difficult materials for example PTFE, polyolefins and polymers to difficult to bond metal such as Silver and Gold
Photo shows static testing of orbital welder core The core relies on multiple hydraulic bearings based on those used in nuclear power stations which asre assembled an innovative configuration. The static test is to prove the complex and innovative journal lubrication feed system and bespoke oil seals which operate in excess of 20m/s.
The orbital Welding Machine uses both Hydraulic bearings and roller bearings. Photo is of the Control Panel specially designed for lubricant feed and Management systemRead More
All component Designs are optimised for Best Performance. Photo shows Hobbing process for cutting splines on drive gear shafts.Read More
Photo illustrates CNC Machining of 75kg Component to be inserted into the orbital welding Machine. Solidworks design Directly drives the CNC manufacture of all componentsRead More
At the outset it would have been impossible to make the concept of the orbital welderwork at large scale. Numerous innovations were needed to address challenges that did not have off the shelfsolutions. One of these was the oil seals: High speed large diameter oil seals with sppeds in excess of 20m/s were sucedssfully together with unique orbital face seals.Read More
Photo depicting adaptor ring for connecting orbital welding core into gear box. Weighing 300 kg and with a diameter of 1.2m it was machined to fit the gearbox casing for maximum structural stiffnessRead More
Jackweld is an engineering design bureau offering consultancy and design and development services for new or improved processes, mechanical components and machinery for industry. Jackweld also has expertise in designing and developing innovative machinery to deliver new industrial processes.Read More
The Jackweld team started as a small group of technicians and engineers in the 1980’s to improve the machinery and processes in the manufacture of prestressed precast concrete. This involved numerous ground breaking innovations, such as through-the-stressed-tendon heating to accelerate the turn around of the plant and increase productivity, which were seen through to successful practical implementation in the factory. The team continued to work as a group of associates for a number of years, and worked on equipment in support to elements of the Army. The group was formed into Jackweld in 2007 as an industrial group for the investigation of the practical implementation of hydro-pillar welding as a manufacturing process for TWI. In addition to general engineering work, the team has been involved in a number of research and development projects with Horizon 2020 and Innovate UK. Jackweld has a core team of experts in a range of fields, and has a long term working relationship with a number of industrial partners.
Jackweld have pioneered a number of technologies such as through-the stressed-tendon heat accelerated curing of pre cast concrete, new methods to monitor the curing of concrete, vibrationless orbital friction welding, and coupling devices for high speed ultrasonic NDT scanning of metals and composite structures.
Our business is problem solving, developing cost effective and low risk routes to deliver solutions.
Our vision is that properly directed, innovation can deliver greater productivity and cost effectiveness, and at the same time improving sustainability and reducing both the environmental impact and the CO2 footprint.
Jackweld has pioneered several innovative hard manufacturing processes. This includes designing and developing various ground breaking machine technologies to implement innovative industrial processes. We carry out basic R&D to identify opportunities for problem solving and improving manufacturing processes. We have long standing working relationships with a number of engineering partners, and out team includes highly qualified and experienced engineers and technologists in areas such as metallurgy, welding, the design and manufacture of rotating machinery, journals, oil seals, structural engineering, production engineering, design optimisation, tolerance analysis. We also have capabilities in 3D modelling, finite element analysis, vibration and computational flow analysis, hydraulics, machine control etc.
Our team comprise highly qualified and experienced engineers and technologists in areas such as metallurgy, welding, rotating machinery, journal design, oil seal design, structural engineering, production engineering, optimising design for machining and tolerances, 3D modelling for prediction and optimisation, finite element and computational flow analysis, hydraulics, machine control etc
Jackweld has pioneered several innovative hard manufacturing processes. This ialso includes designing and developing various ground breaking machine technologies to implement the processes.
With our experienced team and industrial partners, are able to work with external clients offering an economical and low risk service, integrating the various disciplines needed to deliver practical solutions.
This technology has been developed by a consortium of UK and EU companies to weld bainitic steel railway rails, providing a step change improvement in the durability and performance of the rail weld compared to existing processes. The technology welds the rails by friction without causing any vibrations. In this way the rails remain motionless, allowing for the first time ever, large and heavy sections of rail to be friction welded together in the factory or on the track.Learn more
The innovative process has a number of
industrial advantages as follows.
· Enables joining of dissimilar materials and metals considered to have poor weldability using fusion processes.
· Creates narrow heat-affected zone.
· Constant and repeatable weld characteristics due to the inherently resilient orbital friction welding process parameters and highly repeatable process parameters achieved with the machinery.
· Joint preparation is minimal.
· Faster Turn-around Times, in comparison with lead times for forging and machining.
· Increased design flexibility, supports efficient choice of appropriate materials for specific areas of a component.
· Suitable for diverse quantities, from single prototypes to high-volume production
· No fluxes, filler material, or gases required.
· Environmentally friendly process, no fumes or gases generated.
· Solid state process, no weld porosity or slag inclusions.
· Creates cast or forge-like blanks, without expensive tooling or minimum quantity requirements.
· Flexible manufacture of complex parts without reductive machining, reducing tooling costs, production time and swarf waste.
Compliments and expands the exploitation of other solid-state materials processing, e.g. PM-HIP where the control of powder cleanliness concerning interstitial elements (O+N) can have a deleterious impact if exposed to a fusion welding cycle.
Can complement additive manufacturing in joining components into assembles with through-the-cross-section welds, saving time cost and weight, and increasing strength over flange and fitting options. It can also provide a route to welding of bainitic, thixotropic phase alloys, high strength aerospace alloys, and other advanced alloys where fusion or EB welding can detrimentally alter the metallurgical characteristics in the weld zone.
The electro-motive power revolution in the
transport industry is driving the demand for improved strength and reduction in
weight of components and structures. Jackweld is working with a number of
partners looking at the entire light alloy casting line, identifying synergies
and innovations that can be exploited and looking at the following challenges:
· Improved quality of components
· Improved strength of components
· Reduced weight of components
· Reduced tooling costs
· Reduced production costs
· Improved manufacturing flexibility