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11.5m long tube sheets

Product Name:

11.5m extra long tube sheet for environmental protection equipment

Material: Q235

Holes Quantity: 2944

Size: 11500mm×1910mm×25mm

Hole Shape: Round or as required

There are 2,944 holes to be drilled for each tube sheet. The holes need drilling before boring. According to the requirement of the hole diameter of the tube sheets, we drilled it into smaller holes first, and then processed it finely and straightened the plate after the hole was processed. After a strict inspection of the tube sheets, the customer was satisfied with both our processing and service quality and will continue to commission the processing.

11.5m long tube sheets drilling

About Openex

Openex is a leading metal fabricator with rich experience in heat exchanger components, including tube sheets, baffles, and other related products. With over 20 years of experience in the industry, we have established a reputation for delivering high-quality products that meet the most stringent customer requirements. Our advanced CNC drilling machines and skilled workforce enable us to produce custom tube sheets and baffles in large volumes, ensuring timely delivery and customer satisfaction.

If you have any questions or inquiries about tube sheets and baffles or any other metal fabrication services, please do not hesitate to contact us at sales3@openex.com.cn. We look forward to working with you.

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1 Project Background

A sunken ancient ship lies beneath the seabed at the mouth of a sea, covered entirely by underwater sediment. To carry out the conservation and archaeological work of the ancient ship, it is necessary to protect the entire ship and its various artifacts completely. Therefore, in the process of salvaging the entire sunken ship, a non-contact method is employed to salvage the ancient ship as a whole to prevent damage. As a key salvaging device throughout the entire process, this apparatus is mainly composed of components such as side end plates, a top beam, a starting frame, and an arc beam, as illustrated in Figure 1.

Schematic structure of the underwater sunken ship salvaging device

Figure 1 Schematic structure of the underwater sunken ship salvaging device

During the salvaging process, the arc beam components are pre-installed inside the launching frame. The electric motor in the starting frame drives the gear, propelling the arc beam to rotate around the center of the launching frame in a circular motion along the arc rack and the arc roller surface. Several arc beams are connected to form a whole, enveloping the entire sunken ship. The connecting structure between the arc beams is illustrated in Figure 2. Finally, using a lifting beam, all the arc beams, along with the sunken ship, are lifted out of the water.

Schematic of the arc beam connection structure

Figure 2 Schematic of the arc beam connection structure

2 Introduction to Arc Beam Components

The arc beam components are large welded steel structures made of Q355B material, forming a semi-circular structure with a diameter of approximately 20 meters. The cross-section of the arc beam is a rectangular frame structure with outer dimensions of about 1m × 2m. The device comprises over 20 arc beams of the same size and specifications. The structure of the arc beam components is shown in Figure 3.

structure of the arc beam components

Figure 3

3 Precision Requirements for Manufacturing

To ensure the smooth operation of the entire arc beam, there are high precision requirements for the manufacturing of the arc beam. After welding, the dimensional tolerances and geometric tolerances of the inner and outer arcs, as well as the upper and lower planes, must be controlled within ±5mm. After mechanical processing, the arc diameter size accuracy of the inner and outer arc roller grooves and the distance size accuracy between the upper and lower plane arc plate male and female locking slot surfaces must be controlled within ±0.4mm. The perpendicularity tolerance between the male and female locking slot mounting surface of the upper and lower plane arc plates and the roller guide groove mounting surface of the inner and outer arc plates must be controlled within ±0.4mm. The coaxiality of the upper and lower arc roller groove mounting surfaces of the inner and outer arcs must be controlled within ±0.4mm.

4 Welding Fixtures and Welding Process

(1) Welding Fixtures
In order to meet the welding precision requirements of the core arc beam component of the salvaging device, reduce welding deformation, and ensure that the machining allowance on the welding structure of the arc beam is small and uniform for easy subsequent mechanical processing of the mating installation surfaces, the dimensional accuracy of each arc beam, especially the roundness of the arc surface after welding, is controlled within ±5mm. A dedicated welding clamping and positioning fixture for arc beam components has been designed

Overview of Welding Fixture:

A reference point is set on the horizontal ground, a central axis is established perpendicular to the ground, serving as the measurement reference point for the welding fixture of the salvaging device's arc beam. The fixture and parts are oriented with one side near the central axis as the inner side and the opposite side as the outer side. Multiple radial support beams are laid out radially with the central axis as the center, with some instances having 8 radial support beams arranged at equal intervals to form a semi-circle. The radial support beams are arranged in two layers, including bottom radial support beams and top radial support beams. Longitudinal support beams and inclined reinforcing ribs connect the bottom radial support beams, and the top radial support beams provide longitudinal support. Inner and outer positioning blocks are set on the radial support beams. The bottom inner positioning block and bottom outer positioning block are set on the bottom radial support beam, while the top inner positioning block and top outer positioning block are set on the top radial support beam. The outer end face of the bottom inner positioning block and top inner positioning block is at a distance from the central axis equal to the radius of the inner arc surface of the arc beam. The inner end face of the bottom outer positioning block and top outer positioning block is at a distance from the central axis equal to the radius of the outer surface of the outer arc plate of the arc beam. The above errors are controlled within a range of 0.5mm.

(2) Welding Process
The welding process is described as follows:

  1. Use laser cutting equipment to cut the plates, process the sub-parts of the bottom arc plate, inner arc plate, outer arc plate, upper arc plate, and internal reinforcing rib plate. The dimensional accuracy is controlled within 0.5mm. Use a rolling machine for rolling processing, with the arc roundness controlled within 3mm.
  2. Successively hoist the sub-parts of the bottom arc plate, inner arc plate, outer arc plate, upper arc plate, and internal reinforcing rib plate onto the bottom radial support beam. After spot welding each part in place, use a three-dimensional laser detector to recheck the arc accuracy. In specific implementations, hydraulic jacks are used for mechanical correction or flame correction is applied to eliminate dimensional errors.
  3. In specific implementations, control and verify the flatness of the bottom arc plate and upper arc plate. During the hoisting and welding of the sub-parts of the bottom arc plate and upper arc plate, a three-dimensional laser detector and a level are used for flatness rechecks. Dimensional correction is performed for areas where the flatness exceeds 1mm.
  4. Before warehousing, use a three-dimensional laser detector and a level for the final re-measurement of the arc accuracy and flatness of the entire arc beam.

5. Machining Clamping and Positioning Fixture

To address the manufacturing precision requirements and the issue of batch processing for the core arc beam components of the salvaging device, a set of machining clamping and positioning fixtures for the arc beam components has been specially designed, as shown in Figure 4. The main structural features of the clamping and positioning fixture are described below.

Arc Beam Clamping Form

Figure 4 Arc Beam Clamping Form

  1. For machining the arc beam, a vertical lathe with a rotating diameter of up to 20m is used, with a table diameter of 10m and a tool holder travel of 9.5m. Eight radial support beams, each with a length of 11m, are arranged radially along the radial direction with the table's rotating center as the reference point. These support beams extend out from the work table and are connected by outer and inner ring connecting beams, forming a whole that can clamp two arc beams at once. This ensures the rigidity of the machining fixture.
  2. At the upper part of the radial support beams, there are inner arc surface positioning bosses and outer arc surface positioning bosses, making the rotating centers of the arc beam part, the inner arc surface positioning boss, and the outer arc surface positioning boss concentric. The distance from the inner arc surface positioning boss to the rotating center of the work table is equal to the radius value of the inner arc of the arc beam's male-female lock groove, and the distance from the outer arc surface positioning boss to the rotating center of the work table is equal to the radius value of the outer arc of the arc beam's male-female lock groove.
  3. At the upper part of the radial support beams, a radial clamp is installed on one side of the inner arc surface of the arc beam. The radial clamp can not only extend and retract but can also radially clamp and release the arc beam. A top measuring fixture is also installed on one side of the outer arc surface of the arc beam, and it can extend and retract as well as radially clamp and release the arc beam. Additionally, two hydraulic jacks are placed in the middle position between the inner and outer arc surface positioning bosses, allowing adjustment of the height position of the arc beam.

6. Machining Process

The machining process for the arc beam components is described as follows:

  1. Suspend the arc beam fixture on the worktable of a vertical lathe with a machining diameter of up to 20m, install and debug it, tighten the T-shaped clamping bolts on the worktable, and secure the arc beam fixture.
  2. On the machine tool, turn and machine the inner and outer arc surface positioning bosses on the fixture. The distances from the inner and outer arc surface positioning bosses on the fixture to the center of rotation are equal to the radius values of the inner and outer arc surfaces of the arc beam, respectively.
  3. With the upper surface and inner and outer arc surfaces of the arc beam as the process reference, rotate the worktable, align the upper surface and inner and outer arc surfaces with a dial indicator, and adjust the radial position of the arc beam using the radial clamp and top measuring fixture based on the measured values from the dial indicator. This ensures that the rotation center of the arc beam is consistent with the rotation center of the worktable. Slightly adjust the horizontal accuracy of the arc beam using hydraulic jacks to make the horizontal plane of the arc beam parallel to the worktable.
  4. Temporarily weld two arc beam connecting plates to join the two ends of the arc beam into a whole, preventing intermittent cutting during machining.
  5. Perform rough turning, semi-finishing, and finishing in three mechanical machining steps to cut three arc grooves on the lower surface of the arc beam and two arc grooves on the upper part of the inner and outer sides. Throughout the entire turning process, the dimensions of the arc grooves need to be measured multiple times.
  6. After rough turning and finishing, use a three-dimensional laser measuring device to inspect the size of the arc grooves, coaxiality values of each arc groove, and the perpendicularity between the three arc grooves on the lower surface and the two arc grooves on the upper part of the inner and outer sides.
  7. Remove the connecting beams at both ends of the arc beam, lower the arc beam, and flip it.
  8. Recheck, align with a dial indicator, and inspect the arc accuracy and horizontal accuracy of the arc beam.
  9. Using the same processing method as above, complete the turning of the three arc grooves on the upper surface of the arc beam and the remaining two arc grooves on the inner and outer sides.
  10. Remove the connecting beams at both ends of the arc beam, clean, remove burrs, and after passing the final inspection, package the arc beam for storage.

The on-site machining situation in the workshop is shown in Figure 5.

On-site Machining of the Arc Beam

Figure 5 On-site Machining of the Arc Beam

By using the arc beam machining fixture, the positioning and installation of the arc beam can be efficiently and accurately completed. Two arc beams can be installed at once, significantly improving the processing efficiency of the arc beam.

Conclusion

The core component of the underwater salvaging device for the ancient sunken ship, the arc beam, as a super-large welded structural component, requires high manufacturing precision. In the actual production process, using the clamping and positioning fixture and manufacturing process described above ensures not only that each machined arc beam maintains a high level of dimensional consistency but also that all machining accuracies meet the design requirements. The machined arc beam has been successfully used in the underwater salvaging device, completing the salvaging of the sunken ship. This directly confirms the feasibility of the entire arc beam component's machining process and the rationality of the machining fixture structure, significantly improving the production efficiency of the arc beam.

In the ever-evolving landscape of renewable energy, advancements in hydroelectric power generation systems play a pivotal role in shaping a sustainable future. One groundbreaking innovation that takes center stage is the fabrication process of the vertical turbine generator welded structure rotor bracket. This article provides an in-depth exploration of this manufacturing journey, highlighting each crucial step and the transformative impact on the clean energy sector.

Hydrogenerator rotor bracket

Step 1: Design and Engineering Challenges in Traditional Radial Structures

The journey begins with a critical examination of the traditional radial structure of the rotor bracket in a vertical turbine generator unit. This component, although central to the rotor's functionality, presented a host of challenges. Its complex, large, and rigid radial design, subject to intricate forces, required meticulous machining after the rotor shaft's completion. The subsequent thermal fitting of the heated rotor bracket onto the rotor shaft, coupled with the welding of the rib plate, lower ring plate, and hub as an integral unit, posed challenges in maintaining concentricity and incurred significant manufacturing costs.

Step 2: A Paradigm Shift - The Welded Structure Rotor Bracket

The Welded Structure Rotor Bracket introduces a paradigm shift in design philosophy. This innovative approach eliminates the traditional thermal fitting process by adopting an integral welding structure. The core components - rotor shaft, rib plates, upper ring plate, lower ring plate, and vertical ribs - are seamlessly welded together, transforming into a unified and robust integral structure.

Step 3: Benefits of the Integral Welding Structure

The advantages of this integral welding structure are multifaceted. The single-axis design of the rotor shaft, combined with the welding of rib plates on its outer cylindrical surface, provides structural integrity and simplifies the fabrication process. The integration aligns the axis of the rotor shaft precisely with the outer circle of the rotor bracket, eliminating eccentricity issues that plagued traditional radial designs.

Hydrogenerator rotor bracket 1

Step 4: Enhanced Efficiency and Reliability

By aligning the rotor shaft's axis with the outer circle of the rotor bracket, the integral welding structure minimizes axial runout. This reduction significantly enhances the safety and reliability of the vertical turbine generator unit during operation. The elimination of the thermal fitting structure also streamlines the manufacturing process, saving time and reducing costs.

Step 5: Cost-Effective Manufacturing and Reduced Machining

The integral welding structure not only eliminates the need for the hub thermal fitting but also reduces the machining required in the mating section of the rotor shaft and hub. This substantial reduction in machining time and complexity translates to a more cost-effective manufacturing process, aligning with the broader goal of making renewable energy solutions economically viable.

Step 6: Reliability in Torque Transmission

The torque transmission mechanism sees a fundamental shift with the integral welding structure. The weld seam of the rib plates and the rotor shaft replaces the traditional tight fit associated with hub thermal fitting, ensuring a reliable and secure transmission of torque between the rotor bracket and the rotor shaft.

Conclusion

The fabrication process of the vertical turbine generator welded structure rotor bracket not only addresses the challenges posed by traditional radial structures but also heralds a new era in hydroelectric power generation. This innovative approach, with its integral welding structure, sets the stage for enhanced efficiency, reduced manufacturing costs, and increased reliability in the operation of vertical turbine generators. As the global push for clean and sustainable energy solutions intensifies, such advancements underscore the industry's commitment to transformative technologies that pave the way towards a greener and more sustainable future.

If you are inspired by this innovative approach and wish to explore how similar cutting-edge welding structures or metal fabrication solutions can elevate your projects, we invite you to connect with us. Our team of skilled engineers and craftsmen is ready to collaborate with you on any welding structure or metal fabrication requirements you may have. Contact us today at sales3@openex.com.cn to embark on a journey towards efficiency, reliability, and sustainability in your renewable energy endeavors. Let's shape the future together.

Automobile lightweight is the process of reducing the curb weight of a car as much as possible while ensuring its strength and safety performance. This aims to enhance the car's power, reduce fuel consumption, and decrease exhaust emissions. According to a report from the World Aluminium Association, a 10% reduction in the overall weight of a car can lead to a 6%-8% improvement in fuel efficiency. Research by Volkswagen suggests that for every 100-kilogram reduction in the curb weight, carbon dioxide emissions per kilometer can decrease by 8-11 grams, and fuel consumption per hundred kilometers can be reduced by 0.3-0.5 liters. Therefore, in the current context of increasing pressure to reduce emissions from automobiles, lightweight plays a highly positive role in conserving energy, reducing emissions, and achieving sustainable development goals.

 

1.1. Fuel vehicle consumption reduction target is high, vehicle weight reduction can effectively improve fuel efficiency

Lightweighting has become a key focus for the development of fuel vehicles, with a target of a 10% reduction in the overall vehicle lightweighting coefficient for gasoline-powered cars by 2025. Given the goals for reducing fuel consumption in gasoline-powered vehicles, the vigorous development of automotive lightweight technologies and the continuous establishment of a technical development and application system for automotive lightweighting become crucial. The 'Energy-saving and New Energy Vehicle Technology Roadmap 2.0' discards the traditional approach of using the overall vehicle equipment mass and the quantity of lightweight materials as measurement standards. Instead, it introduces the overall vehicle lightweighting coefficient as a basis for assessing the level of vehicle lightweighting. It proposes that by 2025, 2030, and 2035, China's gasoline-powered passenger cars should achieve a 10%, 18%, and 25% reduction in the overall vehicle lightweighting coefficient, while freight trucks, tractors, and buses should achieve reductions of 5%, 10%, and 15%, respectively.

1.2. The weight of the three electric vehicle (EV) power systems is substantial, and the demand to increase driving range is driving the development of lightweight.

In 2022, the penetration rate of new energy vehicles (NEVs) increased rapidly year-on-year, with the national stock of NEVs growing significantly to 13.1 million vehicles. According to statistics from the Ministry of Public Security, the national stock of NEVs reached 13.1 million in 2022, accounting for 4.10% of the total number of vehicles. Deducting the scrapped and deregistered vehicles, this represents an increase of 5.26 million from 2021, a growth of 67.13%. Among these, the stock of pure electric vehicles (EVs) reached 10.45 million, constituting 79.78% of the total NEV stock. In 2022, the national registration of new NEVs was 5.35 million, accounting for 23.05% of the total registered vehicles, an increase of 2.4 million compared to the previous year, marking an 81.48% growth. The number of newly registered NEVs has shown a high-speed growth trend, rising from 1.07 million in 2018 to 5.35 million in 2022.

Compared to traditional fuel vehicles, the demand for weight reduction in new energy vehicles (NEVs) is more urgent:

2. Material, structural, and process lightweight are the three main focuses for reducing the weight of automobiles.

To meet the technical requirements of lightweight casting in the automotive industry, breakthroughs are currently being made in three aspects: materials, structural design, and processes, according to cutting-edge industry technology:

2.1. Material Lightweighting: High-strength steel is currently mainstream, and aluminum alloy shows promising potential.

Among the three major lightweighting methods, material lightweighting serves as the foundation. Based on the use of lightweight materials, the overall vehicle weight is reduced through optimization of structure and upgraded processes. In the development of lightweight materials, the 'Energy-saving and New Energy Vehicle Technology Roadmap 2.0' indicates that China's independent development and application system for lightweight technologies will focus on perfecting the application of high-strength steel in the short term, directing efforts toward establishing a lightweight alloy application system in the medium term, and aspiring to form a multi-material hybrid application system in the long term.

2.1.1. High-Strength Steel: High yield and tensile strength, currently widely applied with potential growth in aluminum alloy.

According to the International Iron and Steel Association's USL-AB project, steel types can be classified based on their mechanical properties into low-strength steel (soft steel), high-strength steel, and ultra-high-strength steel. Low-strength steel has a tensile strength (Rm) of <270MPa and a yield strength (Re) of <210MPa. Ultra-high-strength steel has a tensile strength (Rm) of >700MPa and a yield strength (Re) of >550MPa. High-strength steel falls between these two. Low-strength steel includes IF steel and soft steel; ordinary high-strength steel includes carbon-manganese steel, BH steel, high-strength IF steel, and HSLA steel, among others; advanced high-strength steel (AHSS) includes dual-phase steel (DP steel), transformation-induced plasticity steel (TRIP steel), complex phase steel (CP steel), and martensitic steel (MS steel).

Steel accounts for a large portion of the vehicle's weight, approximately 55-60% of the vehicle's total weight. According to the Automotive Materials Network, in the case of a modern car, steel constitutes 55%-60% of the vehicle's weight, cast iron 5%-12%, non-ferrous metals 6%-10%, plastics 8%-12%, rubber 4%, glass 3%, and other materials (paint, various liquids, etc.) 6%-12%. It is evident that steel usage in cars is significant, and the application of high-strength steel plates can reduce the weight of stamped parts, saving energy and reducing the cost of stamped products. High-strength steel plates used for automotive parts can have a tensile strength of 600-800MPa, while the corresponding tensile strength of ordinary cold-rolled soft steel plates is only 300MPa. Currently, the world's largest steel company, Arcelor, has developed the hot-stamped steel plate USIBOR1500. This galvanized plate has a coating mass of 120-160g/m2, and after quenching, it exhibits significant mechanical properties with a strength value of up to 1600MPa.

High-strength steel can be applied to various parts of a vehicle, including:

Multiple projects confirm that high-strength steel can achieve lightweighting without increasing costs. According to the magazine 'Rolling Steel,' to promote the application of high-strength steel in automobiles, the International Iron and Steel Association has organized several projects, including the UltraLight Steel Auto Body (ULSAB), Advanced Concept Vehicle UltraLight Steel Auto Body Program (ULSAB-AVC), and Future Steel Vehicle (FSV).

2.1.2. Aluminum Alloy: High cost-effectiveness in weight reduction, substantial potential for medium to long-term growth.

Aluminum alloy demonstrates significant advantages in weight reduction, performance improvement, and recyclability. Aluminum alloy, the most abundant green metal in the earth's crust, is not only lightweight and high in strength but also easy to shape, has excellent energy absorption, corrosion resistance, and high recyclability value. Additionally, aluminum alloy, while reducing weight, enhances braking performance, provides better handling, improved driving comfort, and outstanding power for vehicles. According to Automotive Materials Network, specific advantages include:

1) Excellent weight reduction, energy-saving, and emission reduction effects.
2) Improved driving performance, safety, comfort, and stability.
3) High assembly efficiency and ease of recycling.

Aluminum alloy requires fewer spot welds for the overall vehicle body, shortening processing steps. Moreover, it is not prone to rust, eliminating the need for anti-rust treatment, significantly improving the efficiency of car assembly. Additionally, due to its low melting point, low corrosion rate, and mild corrosion during usage, aluminum alloy is easy to recycle.

4) Lower cost compared to carbon fiber and high self-sufficiency in raw materials.

The price of aluminum alloy is only slightly higher than that of high-strength steel and much lower than that of carbon fiber composite materials. The high chemical stability of aluminum alloy makes it less susceptible to corrosion compared to magnesium alloy, limiting its extensive application in the automotive field. Therefore, overall, aluminum alloy is an ideal material for automotive lightweighting at present. In addition, China is the world's largest producer of alumina and electrolytic aluminum, with a high self-sufficiency rate in raw materials.

Aluminum alloy is one of the optimal materials for lightweighting, with considerable potential for medium to long-term growth. Compared to high-strength steel, aluminum alloy has a more pronounced weight reduction effect due to its lower density. Moreover, it does not face issues such as corrosion susceptibility, high processing costs, and the high price of carbon fiber raw materials, which makes recycling more challenging. Furthermore, the excellent metallic properties of aluminum alloy allow for better integration of structural and process lightweighting, achieving comprehensive weight reduction goals. The 'Energy-saving and New Energy Vehicle Technology Roadmap' outlines phased goals for lightweighting in China, with aluminum alloy usage reaching 250kg and 350kg per vehicle by 2025 and 2030, respectively, far surpassing high-strength steel. As the trend toward lightweighting deepens, materials and technologies for lightweighting continue to advance, and aluminum alloy is poised to become the primary material in the automotive market, with clear advantages in long-term growth.

2.1.3. Engineering Plastics: Extending from Interior and Exterior Components to Functional Structural Components, with Broad Development Prospects.

Plastics come in various types and are essential materials for automotive lightweighting. With the emphasis on energy efficiency, emission reduction, and the rise of new energy vehicles, automotive lightweighting has become an industry trend, leading to an increasing use of plastics in automobiles. Based on the different usage characteristics of various plastics, they are generally classified into three types: general plastics, engineering plastics, and specialty plastics. The primary role of engineering plastics in automobiles is to achieve lightweighting, thereby promoting fuel efficiency at high speeds. Developed countries consider the quantity of plastics used in cars as a crucial indicator of automotive design and manufacturing proficiency, with Germany having the highest plastic consumption, accounting for 15% of the overall material usage. According to automotive engineers, replacing some metals with plastics in the high-voltage electrical components of new energy vehicles can reduce weight by around 30% while meeting performance requirements. Currently, using plastic lightweighting in a pure electric vehicle can reduce weight by approximately 100kg, achieving energy savings and emission reduction. The application of engineering plastics in the automotive field has expanded from interior and exterior components to structural and functional parts. According to the Automotive Materials Network, automotive plastics offer many advantages over traditional materials, primarily in terms of being lightweight, providing excellent aesthetic decoration effects, offering various practical application functions, exhibiting good physical and chemical properties, being easy to process and mold, saving energy, and being sustainable.

2.1.4. Carbon Fiber: Greatest Weight Reduction, Hindered by High Costs and Recycling Challenges

Japan and the United States are leading in the development of carbon fibers, while China is accelerating its pace, with the domestication rate reaching 47% in 2021. China's carbon fiber industry started in the 1960s, nearly simultaneously with countries like Japan and the United States. However, due to insufficient knowledge reserves and issues related to intellectual property rights, its development has been slow. Additionally, countries like Japan and the United States have monopolized core carbon fiber technologies, resulting in China's overall lag in carbon fiber production technology and equipment. Since 2000, the country has increased its support for independent innovation in the carbon fiber field, designating it as a key research and development project. With strong support from national policies, the domestic carbon fiber industry has made significant breakthroughs in technology, rapidly increased industrialization levels, expanded application areas, and formed carbon fiber clusters, mainly in Jiangsu, Shandong, Jilin, and other regions. Major domestic companies include Jilin Chemical Fiber, CFEC Shenyang, Zhongcai Sci-Tech, Guangwei Composites, among others. According to Forward Industry Research Institute, in 2021, mainland China's carbon fiber production capacity surpassed the United States for the first time, becoming the world's largest capacity country, with a capacity of 63,400 tons, accounting for over 30% of the global total capacity, and a production volume of 24,300 tons, a YoY growth of 30.03%.

The application of carbon fiber in the automotive sector is hindered by material costs, processing technology, and material recycling challenges. According to the Automotive Lightweighting Technology Innovation Strategic Alliance, key obstacles preventing the widespread use of carbon fiber materials in the field of new energy vehicles include:

2.1.5. Magnesium Alloys: Second Only to Carbon Fiber in Weight Reduction, Corrosion Issues and Manufacturing Challenges Await Breakthroughs

Magnesium alloy exhibits significant performance advantages and finds applications in various areas such as automotive shells, brackets, armrest structures, and automotive display systems. Being the lightest metal material, magnesium alloy boasts features like low density, high strength, excellent heat dissipation, and superior seismic noise reduction performance. The density of die-cast magnesium alloy is only 2/3 of aluminum alloy and 1/4 of steel, with both specific strength and specific stiffness surpassing those of steel and aluminum alloy and far exceeding engineering plastics. Due to its excellent characteristics, magnesium alloy can be used in automotive shells, brackets, armrest structures, and automotive display systems, with relatively high attention and acceptance from market customers for body components such as lamp heat dissipation brackets, dashboard brackets, steering brackets, central control skeletons, and in-vehicle display screen frames.

The forming methods of magnesium alloy materials include casting processing and plastic forming, with manufacturing processes also restricting the widespread application of magnesium in the automotive field.

2.2. Structural Lightweighting: Various Methods Have Their Advantages, and Topology Optimization is Highly Valuable for Pre-optimization

According to 'Research and Progress on Automotive Structural Lightweighting,' structural lightweighting refers to the development and design of components through parameter optimization (dimensions, shapes, positions, thickness, etc.), morphological optimization, and topology optimization. The goal is to reduce weight while maintaining or increasing stiffness and strength.

2.3. Process Lightweighting: Synergistic Development of Various Lightweighting Processes, Wide Application of Hot Forming in the Past Decade

As one of the three main approaches to automotive lightweighting, process lightweighting can effectively help achieve energy savings and weight reduction at the manufacturing level. Lightweighting technology in automobiles aims to integrate lightweight structural design with various lightweight materials and process technologies, considering the characteristics of the adopted lightweight materials, the requirements of lightweight structural design, and the manufacturing technology used to control product costs, all while maintaining or enhancing the performance, safety, and cost-effectiveness of automobiles. Process lightweighting, based on overall lightweight design for automobiles, comprehensively considers the characteristics of adopted lightweight materials, requirements for lightweight structural design, and product cost control in choosing manufacturing technology.

1) Laser Welding: Enables welding of different materials

Laser welding technology involves using advanced laser techniques and equipment to automatically assemble and weld a certain number of materials, such as steel and aluminum alloys, with different materials, thicknesses, and coatings, to form a single integrated sheet. These sheets are then stamped to create components that meet the specific requirements for different components based on their functions, material properties, thickness, and corrosion resistance. Laser welding techniques used in automotive body welding mainly include linear welding, angular welding, curved welding, and multi-part assembly welding. This process uses laser equipment to weld materials with different properties into welded sheets, which are then stamped to produce the final required components, making modern cars both lightweight and energy-efficient.

2) Hydraulic Forming: Shapes complex, high-precision, hollow components in a single forming step

Hydraulic forming uses liquid as a transmission medium. Under the joint action of liquid pressure and the mold cavity, standard pipes or sheets are shaped into structurally complex, single-piece components. This process replaces traditional welding or casting methods, saving processes and maximizing material efficiency. The hydraulic forming technology for high-strength steel can achieve weight reduction and rational space utilization while maintaining safety performance indicators. Hydraulic forming can be divided into sheet hydraulic deep drawing, tube hydraulic bulging, and shell hydraulic forming. According to the difference in the pressure borne by the liquid in the mold cavity, it can be further divided into high-pressure forming and low-pressure forming.

3) Hot Forming: The preferred technology over the past decade

Hot forming technology involves heating sheet metal to the austenite temperature, then hot forming it in the mold. After cooling with water, high-strength martensitic structures are obtained while maintaining the part's good shape. Hot forming addresses drawbacks such as cracking, springback, and wrinkling in the cold forming process. Parts manufactured using this method meet the characteristics of lightweight and high strength, contributing to the lightweighting of automobiles. Over the past decade, hot forming technology has rapidly become the preferred manufacturing technology in the automotive industry.

The three automotive process lightweight technologies have different advantages. In the future, the choice of technology can be based on the characteristics and requirements of different components of the automobile. The biggest advantage of laser welding technology is its ability to weld blanks with different thicknesses, materials, strengths, stamping performance, and surface treatment conditions together before stamping. Hydraulic forming technology excels in shaping complex, high-precision, hollow components in a single step and is suitable for various hollow components with axisymmetric changes in the automotive field, such as exhaust pipes, engines, and subframe main pipes. It has the advantages of increasing the strength and stiffness of formed parts, reducing the number of molds, and lowering production costs. Hot forming technology is suitable for components with high requirements for comfort, strength, and safety. Typical hot-stamped parts include front and rear door side impact bars, front and rear bumper crossbeams, A/B pillars, floor channel, roof reinforcement beams, and suspension fixed brackets. Hot forming achieves the goal of reducing vehicle weight without compromising safety.

4) Pressure Casting: Diverse casting methods, each with its pros and cons

Pressure casting is a casting method that fills the mold cavity with liquid or semi-solid metal or alloy, or liquid metal or alloy containing reinforcing phases, under pressure at a relatively high speed to solidify and form the casting. Pressure casting can be divided into low-pressure die casting, high-pressure die casting, vacuum high-pressure die casting, differential pressure die casting, extrusion casting, etc.

5) Joining Technology: One of the key technologies for lightweight, composite connections complement each other

Joining technology is one of the key technologies for the development of lightweight manufacturing technology. It is related to many aspects such as the performance, weight, processing technology, assembly, safety, and recycling of the connected structure. Traditional joining technologies mainly include resistance spot welding and inert gas shielded welding/reactive gas shielded welding (MIG/MAG). However, with the increasing need for lightweight design of materials, new joining technologies such as laser welding, riveting and self-piercing riveting, bonding, and composite connections have gradually developed and been applied more widely. Mechanical joining technologies include press welding, clinching, self-piercing riveting, blind riveting, and folding. The advantages of using mechanical joining technology instead of resistance spot welding are that it can be used for various material combinations or laminated materials, allows for coated surfaces, does not require heating (low deformation, does not change material properties), and does not require pretreatment and processing. Bonding technology refers to using suitable adhesives as process materials, adopting appropriate joint forms, and using reasonable bonding processes to achieve the purpose of connection. Adhesive connections produce continuous connections, resulting in a more uniform stress distribution. Compared with spot welding and mechanical connections, which are local and intermittent connections, adhesive connections improve connection stiffness.

3. Integration of Die Casting Aids in Cost Reduction and Efficiency Improvement in Vehicle Manufacturing

3.1. Integration of Die Casting for Cost Reduction and Efficiency Improvement, with Equipment Cost, Mold Manufacturing Difficulty, and Material Requirements as Major Barriers

The integration of die casting combines traditional stamping and welding processes in automobile production into a die-casting process, greatly simplifying the manufacturing process. Traditional automobile manufacturing consists of four major processes: stamping, welding, painting, and final assembly. Stamping involves pressing metal sheets into various components needed for the vehicle body, followed by welding or riveting to produce large aluminum parts. In contrast, integrated die casting uses large-tonnage die-casting machines to combine stamping and welding into a single die-casting step, merging the first two steps into one. This process highly integrates multiple individual and dispersed components, directly casting large parts.

Compared to the traditional 'Stamping + Welding' model, the integrated die casting model demonstrates advantages in several aspects:

1) Triple cost reduction in production line, materials, and labor.

2) Simplified process flow and increased production efficiency.

The traditional manufacturing process for car bodies mainly consists of four stages: stamping, welding, painting, and final assembly. The main car manufacturers purchase various structural components manufactured by suppliers nationwide through stamping and die-casting, assembling them (including welding, riveting, and gluing) to form the car's body-in-white assembly. In contrast, the integrated die-casting process reduces the workload of stamping and welding and eliminates many gluing process steps, resulting in a significant increase in production efficiency. For example, the Tesla Model Y's rear floor uses integrated die-casting, where all parts are die-cast in one step, applying new alloy materials. The rear floor assembly, cast in one piece, no longer requires heat treatment, reducing manufacturing time from 1-2 hours in traditional processes to 3-5 minutes.

3) Reduction in body weight, decreasing the amount of installed batteries.

According to Cheqian Information, the cost reduction of batteries is 6.6 times that of the cost increase from switching to aluminum body materials from steel. The next-generation integrated die-cast chassis from Tesla is expected to reduce vehicle weight by 10%, corresponding to a 14% increase in range. For example, using an 80 kWh battery capacity for a typical electric vehicle, adopting an integrated die-casting body for weight reduction while maintaining the range can lead to a reduction of about 10 kWh in battery capacity. Calculated based on a cost of 100 dollars/kWh for lithium iron phosphate battery packs, this can reduce costs by 1,000 dollars.

All these advancements in lightweight technologies, structural optimization, manufacturing processes, and die casting integration collectively aim to enhance efficiency, reduce costs, and contribute to the development of lighter and more sustainable vehicles in the automotive industry.

We are excited to announce the impending delivery of the first batch of large stainless steel storage tanks as part of a project catering to the needs of a new energy customer. This venture has been a testament to our commitment to excellence and innovation in the field of metal fabrication.

storage tank fabrication

Project Overview:

This storage tank fabrication project presented unique challenges due to the design featuring a relatively thin cylindrical body and a substantial volume. The key concern was controlling deformation during the intricate manufacturing process, which includes cutting, forming, welding, surface treatment, and more.

storage tank fabrication - welding

Strategic Approach:

To meet the demands of our new energy customer and expedite the production schedule, we formed a dedicated project team. This team worked diligently to optimize the manufacturing process, ensuring cost-effectiveness for the customer. The collaborative effort resulted in a detailed processing plan that systematically guided each step of production, enhancing efficiency and ensuring seamless progress.

Customer-Centricity and Quality Control:

Throughout the project, our team has unwaveringly adhered to the service philosophy of customer-centricity. We have implemented a stringent quality control system, meticulously supervising every detail to guarantee the highest standards. This commitment to quality has been the cornerstone of our success in delivering a product that not only meets but exceeds customer expectations.

storage tanks fabrication

Achievements and Confidence Boost:

The successful and smooth progress of this initial batch of storage tank projects has significantly boosted our confidence. It serves as a testament to the effectiveness of our one-stop metal fabrication services, showcasing our ability to handle complex projects with precision and expertise.

Future Endeavors:

Looking ahead, we are poised to capitalize on this success by expanding our reach in both domestic and international markets. Our commitment is to continually enhance our service awareness, actively strengthen and refine manufacturing services, and foster mutually beneficial development with our customers.

In conclusion, this project stands as a shining example of our capabilities in overcoming challenges, delivering high-quality products, and fostering collaborative relationships with our valued customers. We remain dedicated to innovation, excellence, and the pursuit of new opportunities in the ever-evolving landscape of metal fabrication.

We invite you to explore the possibilities of partnering with us for your metal processing needs. Whether it's a unique project requirement or a standard manufacturing service, our dedicated team is ready to collaborate, innovate, and deliver excellence. Contact us at sales@openex.com.cn today, and let's embark on a journey of successful and mutually beneficial partnerships.

Project Overview

In response to a recent demand for metal parts required in the fabrication of lithium powder drying equipment, our team undertook the challenge of producing components made from Q235B carbon steel. The intricacies of this project lay not only in the material itself but also in the complex processing requirements, including cutting, tapping, bending, and a stringent demand for precision by the customer.

metal parts fabrication for Lithium Powder Drying Equipment

Material and Processing Details

The chosen material, Q235B carbon steel, known for its excellent weldability and formability, posed as a reliable choice for the specific needs of lithium powder drying equipment. The processing involved a multi-step approach, including cutting, tapping, bending, and other precision processes. Each step required meticulous attention to detail to meet the high precision standards set by the customer.

Challenges Faced

The project was not without its challenges. The customer's exceptionally high precision requirements necessitated a thorough evaluation of our manufacturing processes. The challenges included maintaining precision across various processing methods, optimizing the production timeline, and ensuring minimal material wastage.

Service Plan Formulation

To address these challenges, we developed a comprehensive service plan tailored to the unique demands of the project. The service plan encompassed:

  1. Process Flow Control: A detailed analysis of the entire production process was conducted to identify critical points where precision could be maximized. This involved a thorough review of the cutting, tapping, bending, and other relevant processes.
  2. Node-Level Control: Each processing node was subjected to stringent control measures. Advanced quality control mechanisms were implemented to monitor and ensure precision at every stage. This not only enhanced the overall quality of the parts but also contributed to a more efficient production process.
  3. Duration Shortening: Recognizing the importance of time in meeting project deadlines, we implemented strategies to streamline the production timeline. This involved optimizing the workflow, reducing unnecessary steps, and employing advanced manufacturing techniques.
  4. Material Saving: A focus on sustainability led us to minimize material wastage. Precision cutting and optimization of raw materials contributed to significant material savings without compromising on the quality of the final product.

metal parts bending for Lithium Powder Drying Equipment

Results and Customer Satisfaction

The implementation of the service plan yielded positive results. The metal parts were successfully fabricated, meeting the high precision standards set by the customer. The project was completed within the stipulated timeframe, showcasing not only our commitment to quality but also our efficiency in project management. The customer expressed satisfaction with the final product, praising our dedication to precision, timely delivery, and sustainable manufacturing practices.

Lithium Powder Drying Equipment fabrication

Lithium Powder Drying Equipment

Lithium powder drying equipment plays a crucial role in the production of advanced energy storage systems, particularly in the manufacturing of lithium-ion batteries. This specialized equipment is designed to efficiently remove moisture and enhance the quality of lithium powder, a key component in battery technology. As the demand for high-performance batteries continues to rise, the importance of reliable drying processes becomes increasingly evident.

Key Components and Functionality

The lithium powder drying equipment typically consists of several key components:

Significance in Battery Production

The quality of lithium powder directly influences the performance and lifespan of lithium-ion batteries. Excess moisture in lithium powder can lead to performance degradation, reduced energy density, and safety concerns. The lithium powder drying equipment addresses these issues by ensuring that the lithium powder meets strict moisture content specifications, resulting in batteries with enhanced efficiency and reliability.

Conclusion

The successful fabrication and delivery of Q235B carbon steel parts for lithium powder drying equipment underscore our commitment to overcoming challenges with innovative solutions. This project exemplifies our capability to tailor service plans to meet the unique demands of each project, ensuring customer satisfaction and establishing our position as a reliable partner in precision manufacturing.

Ready to embark on your next project with us? Whether you have specific precision manufacturing needs or seek a trusted partner for your intricate metal fabrication requirements, we are here to deliver excellence. Contact us today to discuss how our expertise can elevate your project to new heights. Let's transform challenges into opportunities and bring your vision to life through precision engineering.

In a recent venture, Openex, a professional metal fabricator, achieved remarkable success in the fabrication of ducts and other essential steel structure components for a ferronickel project undertaken by a prominent metallurgical equipment company. The project's significance was magnified as the quality of the fabricated products garnered high praise and recognition from the client, showcasing Openex's commitment to excellence in metallurgical fabrication.

ductwork fabrication

Scope of Work

The metal components crafted for this ferronickel project encompassed a variety of structures, prominently featuring ducts and duct supports. The materials utilized included Q355B and Q235B steel with thicknesses ranging from 4mm to 40mm. The fabrication process embraced a series of intricate procedures, such as cutting, edge milling, bending, welding, and painting. Each step was meticulously executed to ensure the final products met stringent quality standards.

Fabrication Process

The project commenced with a detailed planning phase, where the team at Openex meticulously analyzed the project requirements and devised a comprehensive strategy. Drawing decomposition, process splitting, and welding operations were intricately planned to optimize efficiency and minimize any potential bottlenecks in the production process.

Cutting-edge technology and precision machinery were employed in the fabrication process. The raw materials, Q355B and Q235B steel, were subjected to cutting processes to achieve the specified dimensions. Following this, edge milling and bending operations were carried out with utmost precision to ensure the accurate alignment and structural integrity of the components.

Welding, a critical phase in steel fabrication, was executed with the highest standards of craftsmanship. Openex's skilled welders meticulously joined the steel components, ensuring the structural integrity and durability of the final products. Post-welding, the components underwent a thorough inspection to guarantee they met the required specifications.

The final touch involved the application of protective coatings through a meticulous painting process. This not only enhanced the aesthetic appeal of the components but also served as a crucial layer of defense against corrosion, especially given the nature of the ferronickel environment.

air ducts welding

Project Execution

The project unfolded seamlessly, with every aspect of the production process carefully monitored and managed. Drawing on their extensive expertise, the Openex team adeptly decomposed the intricate project drawings, streamlining the subsequent processes. Process splitting, a key strategy in managing complex fabrication projects, was implemented effectively, allowing for parallel execution of tasks without compromising quality.

The welding operation, a pivotal stage in the fabrication process, was carried out with precision and efficiency. Openex's team of experienced welders ensured that every weld joint met industry standards and adhered to the project specifications. This meticulous approach not only contributed to the overall quality of the components but also played a crucial role in completing the production schedule ahead of the planned cycle.

Despite the project's complexity, Openex's commitment to excellence and efficient project management enabled the completion of key components well before the scheduled timeline. This not only showcased the company's prowess in meeting project deadlines but also demonstrated its ability to navigate challenges effectively.

air ducts supports fabrication

Quality Assurance

Openex prioritizes quality assurance at every stage of the fabrication process. Rigorous inspections were conducted to ensure that the finished components met the highest industry standards. Before shipping, each batch of finished parts underwent a thorough rust-proofing process to enhance their longevity, especially in the demanding environment of a metallurgical facility.

Customer acceptance tests were successfully conducted, and the products received high praise from the client. The meticulous attention to detail, from fabrication to finishing, was evident in the final products, leading to a seamless acceptance process.

Conclusion

In conclusion, Openex's successful completion of the ducts and steel structure components for the ferronickel project stands as a testament to the company's commitment to excellence, efficiency, and quality. The project showcased Openex's proficiency in managing complex metallurgical fabrication tasks and its ability to exceed customer expectations. As the fabricated components are shipped and integrated into the metallurgical equipment, Openex continues to set the benchmark for excellence in the fabrication industry. The success of this project reinforces Openex's position as a reliable partner for metallurgical ventures, capable of delivering exceptional results with precision and expertise.

As we celebrate the success of this project, we invite you to explore the possibilities of collaboration. Whether you have a metal fabrication project or seek a reliable partner for your manufacturing endeavors, Openex is here to bring your vision to life. Contact us today at sales3@openex.com.cn to discuss how our expertise and commitment to quality can contribute to the success of your next project. Let's build excellence together.

In a recent achievement, our workshop proudly announces the successful fabrication of a batch of stainless steel weldments that not only ensured production efficiency but also marked a significant breakthrough in shaping precision. This accomplishment garnered high recognition from our esteemed customer, highlighting our commitment to delivering top-notch quality in every project.

long steel weldments

Weldment Composition and Customer Demands

The weldment in question comprises three meticulously bending parts, intricately spliced and welded to form an impressive total length of 24 meters. The customer, discerning in their requirements, placed a premium on the flatness of the final product. This presented a unique challenge as the workpiece, necessitating multiple support rods for welding, experienced considerable deformation post-welding.

extra long weldments

Challenges in Calibration

Addressing the issue of post-welding deformation proved to be a complex task for our production department. Traditional methods involving the use of jacks or hammers for calibration were envisioned but proved inefficient and challenging in terms of ensuring precision. The conventional approach added undue pressure to the production timeline, necessitating a more innovative solution.

Innovative Calibration Solution

After thorough discussions and brainstorming sessions, a decisive step was taken to employ a 2000T bending machine for calibration. Leveraging the team's wealth of experience in calibrating molded parts, a series of meticulous steps were taken to refine the calibration process. This involved repeated parameter modifications, the creation and testing of numerous samples, and rigorous test confirmations.

Remarkable Results

The collaborative efforts of our skilled team, combined with the strategic use of the 2000T bending machine, resulted in the successful completion of a batch of high-precision calibrations. The initial workload estimate of one week was astonishingly shortened to a mere two days, showcasing the remarkable efficiency and accuracy achieved through this innovative approach.

Conclusion

This breakthrough in stainless steel welding and precision calibration exemplifies our commitment to overcoming challenges with innovative solutions. By embracing advanced technologies and drawing on our collective expertise, we not only met but exceeded customer expectations. This success story underscores our workshop's dedication to pushing boundaries and setting new standards in the field of metal fabrication.

As a professional metal fabricator, we invite you to experience the difference that our cutting-edge solutions and unwavering commitment to quality can bring to your projects. Whether you have complex welding needs, intricate calibrations, or unique metal fabrication requirements, our skilled team is ready to collaborate and deliver exceptional results. Contact us today at sales3@openex.com.cn to explore how our expertise can elevate your metal fabrication endeavors to new heights. Your success is our priority, and we look forward to being your trusted partner in precision and excellence .

In our metal fabrication workshop, something exciting happened recently. We were given the task of making strong crane arms for big trucks. This was a big deal for us because it showcased our skill in making high-quality metal parts.

metal bending parts for Cranes

Building Trust

Before this project, our customer checked us out thoroughly. They wanted to make sure we were good at what we do. They looked at our past work, how we control quality, and our fabrication ability to handle similar projects. After all this, they decided to trust us with this important job.

Testing the Products

On November 5th, we started making a few crane arms to test our process. We were making them for two types of cranes, one that can carry 35 tons and another that can carry 55 tons. Each type had five upper arms and five lower arms, making a total of 20 sets and over 200 pieces.

Exceeding Expectations

The test went really well. The crane arms we made didn't just meet our customer's expectations; they were even better. This showed that our team is dedicated and careful when it comes to making high-quality parts.

bending parts for Steel Crane Arms

Making Precision a Priority

This project had some very strict rules. Our customer wanted the crane arms to be a certain shape, straight, round, and meet other specific requirements. To make sure we got all these details right, we used a powerful machine called a 3000-ton bending forming machine.

This machine can adjust things very precisely. It can correct any bending problems at 26 different points over a length of 15 meters. This helps us make sure all the crane arms have the same angles, and it stops any problems caused by wear and tear on the machine or uneven pressure on the metal.

By using this machine, we made sure that the crane arms fit perfectly. This means they work really well when they are put together, making the trucks safe and efficient.

3000 ton brake press

Looking to the Future

As we keep working on this project, it's clear that our careful approach will help our customer a lot. The crane arms we are making will not only make the trucks better but will also save our customer money and time.

We're proud to use the best technology and make sure our products are high quality. We believe that our crane arms will become a new standard for the industry, helping trucks work better and safer.

Conclusion

The story of making high-strength steel crane arms for commercial trucks is all about how we care about doing our best work. Our customer trusted us, and we didn't disappoint. We used high-tech machines and followed strict rules to make sure the crane arms are just right.

As we keep making these important parts, we're excited about how they will make trucks work better and be safer. Our dedication to quality and precision shines through in every crane arm we produce. We're looking forward to the positive impact our work will have on the industry and how our crane arms will make commercial trucks safer and more efficient around the world.

If you have metal fabrication needs or are looking for high-quality parts that meet strict standards, we're here to help. Our commitment to precision and innovation is at the core of what we do. Contact us at sales3@openex.com.cn today to discuss your project and experience the difference of working with a dedicated and skilled team. Together, we can bring your ideas to life with excellence and reliability.

In metal fabrication, the pursuit of excellence knows no bounds. Metal fabricators are often tasked with creating intricate components that play a pivotal role in groundbreaking projects. Recently, we had the privilege of being part of an ambitious endeavor - the manufacturing of vacuum chamber for the Fusion Engineering Test Reactor (FETR). This chamber is a crucial element in a large-scale tokamak fusion project, designed to push the boundaries of fusion technology and contribute to addressing the global energy crisis.

vacuum chamger fabrication for FETR Project

A Glimpse into the FETR Project

The FETR project is more than just a scientific exploration; it represents the collective aspirations of the international scientific community to conquer the ultimate energy problem facing humanity. This monumental undertaking strives to research key technologies not included in the International Thermonuclear Experimental Reactor (ITER) and bridge the gap between ITER and the future demonstration power station (DEMO). By doing so, it aims to pave the way for harnessing fusion energy, a virtually limitless and environmentally friendly source of power.

The Vacuum Chamber: The Heart of FETR

At the heart of the FETR project lies the vacuum chamber, a critical component without which nuclear fusion cannot occur. The vacuum chamber serves as the controlled environment for plasma generation, combustion, and maintenance during the fusion reaction. This complex structure is characterized by its substantial size, demanding parameters, heavy load-bearing requirements, and significant exposure to radiation. As a result, constructing a vacuum chamber of this magnitude and complexity requires unwavering dedication and expertise.

Meeting Stringent Requirements

The fabrication of the FETR vacuum chamber presented a unique set of challenges. The stringent requirements for construction quality were a top priority. Our team of metal fabricators rose to the occasion, leveraging advanced processing equipment and their extensive experience to ensure the successful completion of this pivotal project. The vacuum chamber had to meet exacting standards in terms of precision, material strength, and radiation resistance to guarantee the safety and efficiency of the fusion reaction.

The Role of Advanced Equipment

To meet the high demands of the FETR vacuum chamber, we harnessed the potential of cutting-edge processing equipment. This equipment enabled us to carry out intricate metalwork with unparalleled precision and speed. By pushing the boundaries of our machinery, we ensured that the vacuum chamber could withstand the extreme conditions it would encounter during the fusion process.

Recognition from Expert Panels

Our efforts did not go unnoticed. The vacuum chamber we fabricated was subjected to rigorous inspection by a panel of experts from the FETR project. Their evaluation revealed that our work not only met but exceeded their expectations. The recognition and approval of the expert group serve as a testament to the dedication and expertise of our team in contributing to the advancement of fusion technology.

Conclusion

The successful fabrication and delivery of the FETR vacuum chamber mark a significant milestone in the pursuit of fusion energy. This project is not just a testament to the capabilities of our metal fabricators but also a remarkable stride forward in the quest for a sustainable and virtually limitless energy source. We are honored to have played a part in this groundbreaking endeavor, and we remain committed to pushing the boundaries of what metal fabrication can achieve in the realm of cutting-edge science and technology. As we celebrate this achievement, we eagerly look forward to the brighter, cleaner, and more sustainable energy future that fusion technology promises to deliver.

Your Trusted Partner in Vacuum Chamber Fabrication

At Openex, we take immense pride in our extensive experience in the fabrication of vacuum chambers, flanges, components, and vacuum chamber systems. With a rich history that includes the successful fabrication of thousands of vacuum chambers, we have honed our expertise in constructing these intricate structures. Our proficiency extends across various industries, including Flywheel Energy Storage, Solar, Optics, Aerospace, Vacuum Casting, Crystal Growth, Thin Film Deposition, and more.

Whether you require compact vacuum chambers or large, heavy-duty metal fabrication, we are equipped to meet your project needs. Our commitment to precision and excellence ensures that your vision becomes a reality. Partner with Openex to harness our expertise and cutting-edge equipment for your next venture in metal fabrication. Together, we can embark on a journey towards groundbreaking achievements and a sustainable future powered by fusion technology. Contact us at yuki.zhou@openex.com.cn today to discuss your project requirements and explore the possibilities of collaboration.

About Openex

Openex is home to a full-service, one-stop-shop, contract manufacturing company producing custom large machined parts and fabrications. Our full large fabrication services including large machining, cutting, welding, rolling, punching, braking, testing, painting, and others.
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