Screwed, welded, riveted, and bonded solutions – precision connections

– naturally

Welding

Welding thin-gauge materials for lightweight design components demands a lot of experience.

With Sykatec you have the right partner for all kinds of welding tasks, including all the necessary certification.

industrie-schweissen-sykatec

non-destructive testing of the weld with ultrasound

Facts:

Precision welding produces large-scale components in lightweight design

  • All the standard welding processes: Spot welding, nut welding, stud welding with MIG, MAG or TIG technology
  • Manufacture of complex modules for a range of applications
  • Performance and documentation of tests and acceptance procedures

Certified:

EN 15085-2 Welding of railway vehicles
EN ISO 3834-2 Quality requirements for fusion welding
DIN 2303 Quality requirements for military products

SYKATEC’s equipment includes 12 rotary, tilting, and elevating welding tables for components up to 5 m in length and 2.40 m wide.


Laser welding

Computer-assisted laser technology makes it possible to produce more accurate weld seams quickly and in the highest quality.

In addition to processing the material without distortion, laser welding is also energy-efficient.

Because the process is perfectly coordinated with the material used, less heat needs to be applied.

Thanks to our experience, we deliver perfect pieces in the best possible quality.

without distortion and energy efficient

Facts:

Economical manufacture using a robot-assisted laser welding system:

Laser-welded components up to 1.40 m long and 1.40 m wide

A shuttle table optimizes equipment use while work is in progress

With laser-welded parts there is no need for post-processing, and finishing work can be performed immediately.


Friction stir welding (FSW)

Friction stir welding (FSW) is a special element in SYKATEC’s portfolio. This process was developed in Cambridge 20 years ago as a means of welding aluminum with no need for flux or filler material.

The workpieces are welded together in a single pass with high precision and at a lower temperature than with traditional welding.

Aluminum up to 28 mm

Facts:

Welding of solid cooling plates up to 28 mm thick

technical performance limit at a width of 60 cm – The machine will take all standard extruded profiles

We have already manufactured tens of thousands of radiator plates using this special process. 


Bonding and sealing

Bonding technology is used mainly where the risk of material damage caused by drilling holes must be avoided, or where different materials have to be joined together.

The expertise of SYKATEC is evident in the various bonding processes it applies, particularly those with a sealing function for applications in humid environments, and the bonding and sealing of large workpieces.

also sealing function in humid environments

Facts:

Processing coated and uncoated surfaces in accordance with DIN 6701-2 A3

Almost all materials can be joined to the same or other materials

Bonding creates a visually appealing surface and provides additional surface protection

In lightweight design applications, strong adhesive forces can be transmitted between very thin adherends

Every year, Sykatec creates more than 100 km of seal welds or bond seams.


Riveting

Riveting is one of the most standard joining technologies in the industry.

This cost-efficient method is most suited to cases in which the solid connection will not need to be broken again, and the connection has to be durable.

Naturally, we will always offer you the right solution for your needs and advise you which joining technology is most suitable for your project.

cost-efficient method

Facts:

Riveting of all parts made in the sheet metal unit

State-of-the-art technology ensures highly accurate results

Proven procedure


TOX® clinching

TOX® clinching, or just clinching, is a patented cold welding method that enables sheet metal components to be joined with no need for additional elements.

TOX® clinching is used in cases where spot welding is unsuitable. The positive combination achieved in just a short time in this way results in perfect, robust workpieces.

Connections without additional elements

Facts:

1 – 1.5 mm connections

2 – 3 mm connections

Materials: Suitable for aluminum and galvanized material

A clinched connection can achieve static stability of up to 1.5 times that of spot welding. 

From material to module

– naturally

Welded modules

SYKATEC produces and supplies welded modules in compliance with DIN EN 15085-2.

The modules are made in accordance with customer specifications. All the required tolerances are established using smart clamping and welding systems, with no mechanical post-processing.

Relatively thin-gauge source materials can be used to keep weight to a minimum.

Welded modules DIN EN 15085-2

Facts:

All welding technologies from manual to laser welding

Perfect logistics, certified skilled operators

Lightweight design workpieces 5 m x 2.40 m x 0.8 m

Our certified weld seams must last for a minimum of 30 years, which we guarantee


Bonding modules

The question of bonding and sealing is increasingly important when it comes to processing workpieces. In combination with various bonding methods, riveted connections in particular acquire further beneficial properties essential for particular areas of application.

Bonding according to DIN 6701

Facts:

Separate bonding rooms with certified atmospheric humidity enable bonding in accordance with DIN EN 6701

All technologies available: Bonding with intermediate layers or further processing techniques are performed with experience and skill

Tested bonding specialists ensure the bonding technology is perfectly performed.


Riveting modules

Our assembly department will provide you with a ready-to-install riveted module if required, and can also provide large series runs on a just-in-time basis.

Tight logistical connections enable us to offer a range of mechanical riveted modules in the correct quantities, which are integrated directly into the customer’s supply chain.

Even large series just in time

Facts:

Every year, 20,000 riveted modules are fed into our customers’ production lines on a just-in-time basis

All modules undergo final testing – no exceptions

Need components or modules?

We’ll provide you with top-quality advice at every stage of the manufacturing process! contact now

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