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
Welcome to Jackweld, your go-to engineering design consultancy that specializes in the development and design of innovative processes, mechanical components, and machinery for the industry. Our expertise doesn't stop there; we also excel in crafting groundbreaking machinery that paves the way for fresh industrial processes. At Jackweld, we go beyond providing services – we partner with you to revolutionize your industry.
Since its inception in the 1980s, our collective has been dedicated to offering technical solutions for a myriad of industrial challenges, initially focusing on the local industries. Originating as a technical cooperative, we collaboratively worked with numerous local businesses and proficient engineers, thus contributing to the industry's technical development.
Our initial success was seen in the enhancement of machinery utilized for precast and extruded concrete production, addressing significant manufacturing issues. The subsequent projects saw us pioneering productivity-boosting innovations like the inception of concrete heating through tendon resistance.
Originally composed of a close-knit group of associates and numerous industrial partners, we benefited from direct access to high-grade machining and engineering facilities. Primarily, our work was concentrated on servicing the companies within our group.
However, in the early 2000s, our structure evolved, and we were formally incorporated. This significant move allowed us to extend our services beyond our group, facilitating technical collaborations with external entities, including The Welding Institute.
Over the years, we've expanded our reach, undertaking developmental work for numerous organizations across the UK and EU. Our portfolio of work includes transducer coupling systems, bespoke friction welding machines, and more.In recent years, we've continued to grow and innovate, dedicating significant resources towards the development of new processes. For instance, over the past three years, we've invested in excess of 300 man-hours in advancing aluminium alloy processing techniques.
Continuing in this vein, we persist in our commitment to both internal development and contributing to broader industrial progression, maintaining our position at the forefront of technical solutions.
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 stands as a pioneer in advanced hard manufacturing processes, leading the industry with our unique and groundbreaking machine technologies. As leaders in the evolution of industrial processes, we continually engage in core R&D to pinpoint opportunities for problem-solving and to enhance manufacturing operations.
Our experienced team, boasting expertise in areas such as metallurgy, welding, rotating machinery design and production, journals, oil seals, structural and production engineering, design optimization, and tolerance analysis, fuels our innovation. Moreover, we extend our proficiency to 3D modeling, finite element analysis, vibration and computational flow analysis, hydraulics, and machine control, amplifying our diverse suite of capabilities.
Our long-standing collaborations with numerous engineering partners testify to our reliability and commitment. Here at Jackweld, we don't just develop cutting-edge machine technologies; we redefine the future of industrial processes.
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.
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.
Orbital Friction Welding
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
A number of transducer coupling devices have been developed for specific applications, for example long term monitoring of rails, testing aircraft wiring loom bundles for insulation defects, and high speed scanning of composite airframes and keeping mine processing valves clean.