ALJO ALUMINIUM-BAU JONUSCHEIT GMBH INNOVATION IN ALUMINIUM PROCESSING
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1 ALJO ALUMINIUM-BAU JONUSCHEIT GMBH INNOVATION IN ALUMINIUM PROCESSING
2 ABOUT ALJO / LOCATION
3 ABOUT ALJO / FACTS & FIGURES EXPERTS IN ALUMINIUM PROCESSING More than 40 years experience Family owned 300 employees Turnover of 30 million Euros Production area of sqm Quality Management System according to aerospace, automotive and marine international standards
4 ABOUT ALJO / FACTS & FIGURES THREE DIVISIONS UNDER ONE ROOF AEROSPACE MARINE AUTOMOTIVE
5 ABOUT ALJO / PORTFOLIO CORE COMPETENCIES Type of Production: Prototypes Low and high volume series Small series Component manufacturing Assemblies Complex projects Project Management steps: Design and development Engineering / construction Manufacturing Assembly Delivery logistics After Sales Service / Refits
6 AEROSPACE DIVISION
7 AEROSPACE DIVISION / AVIATION AEROSPACE For more than three decades Aljo has been a proven supplier for machined or sheet metal formed aluminium components, assemblies and complex structures with certified aerospace process approvals. As a build to print partner we offer manufacturing solutions for prototypes and single parts as well as small and large series. perfect functionality for you!
8 AEROSPACE DIVISION / GENERAL CORE COMPETENCIES Material procurement Production planning Tooling Manufacturing Surface treatment Final inspections Delivery logistics Inventory logistics for clients Assembly
9 ABOUT ALJO / MANUFACTURING PROCESSES MANUFACTURING PROCESSES 2D sheet metal machining 3D milling (five axis) Turning Deep drawing and press forming Bending Heat Treatment Welding Gluing Surface treatment (powder coating, liquid coating) Assembling Quality inspection Our best practices approach to manufacturing is mirrored in our approach to customer service. Build to print (QSF-B) approved for more than 20 years
10 ABOUT ALJO / MANUFACTURING PROCESSES 2D-MACHINING 3 PORTATEC PORTAL MILLING MACHINES Control unit: Siemens Sinumerik 840D Working area (xyz): 3.400x1.500x250mm Spindle speed: max rpm & 12KW Toll storage capacity: 24 2D-MACHINING
11 ABOUT ALJO / MANUFACTURING PROCESSES MILLING 3 AND 5 AXIS MACHINE CENTERS 3D-MACHINING
12 ABOUT ALJO / MANUFACTURING PROCESSES MOULDING PRESS Size: length mm width 800 mm height 400 mm DEEP DRAWING/ PRESS FORMING
13 ABOUT ALJO / MANUFACTURING PROCESSES BENDING MACHINE Size: length mm BENDING
14 ABOUT ALJO / MANUFACTURING PROCESSES HEAT TREATMENT OVEN Furnace with 2 electrically operated circulating air oven. NADCAP approved SPC controlled handling system Quench basin Time to quench < 10s Automated documentation of process HEAT TREATMENT FACILITY
15 ABOUT ALJO / MANUFACTURING PROCESSES WELDING SKILLS DIN EN ISO DIN 2303 class Q1, Q2 & Q4 Aluminium constructions SIN EN ISO ISO B1, C1 & D (chromium-nickel steel, titan and aluminium) EN EWE welding engineers & welding specialists acc. DVS-EWF 1173 WELDING
16 ABOUT ALJO / MANUFACTURING PROCESSES GLUING SKILLS Adhesive specialists acc. DVS 3301 Adhesive bonder acc. DVS 3305 Manually & partly mechanised processing of reactive adhesive systems Separate bonding room with separate area for silicon treatment GLUING
17 ABOUT ALJO / MANUFACTURING PROCESSES COATING FACILITIES Liquid Coating Drying chamber with for parts up to part size: H/W/L 2.500/3.000/6.000 mm Integrated conveyor systems Powder Coating Max. size x 700 x mm Pre-treatment with phosphatisation facility Furnace to 220 C COATING
18 ABOUT ALJO / MANUFACTURING PROCESSES MEASURING EQUIPMENT Air conditioned measurement area Tension testing machine Material testing machine Extensive measurement equipment Zeiss Prismo 10 Navigator Mora-AEH Range x x mm Mobile index arm Faro Type: Quantum (7 axes) QUALITY INSPECTION
19 AEROSPACE DIVISION / AVIATION AVIATION
20 AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS LOAD MASTER WORK STATION This project for the latest A400M military transporter presents a unique challenge. The Load Master Work Station is a complex assembly which has to be built according to exclusive military specifications and procedures
21 AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS AIR DISTRIBUTION DUCTS This welded part is made of deep drawn thin sheet metal components for various Airbus types. We set up new production lines to meet the demands of this project
22 AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS DRAIN-MAST These welded parts are mounted on almost all Airbus Types. Automated production and the latest in welding technology guarantees the ultimate in production efficiency and quality
23 AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS DIFFUSOR T900 Highly complex forming and welding part made of stainless steel for A380 Airbus aircraft engines
24 AEROSPACE DIVISION / AVIATION PRODUCT SOLUTIONS COMPONENTS More than single parts and subassemblies per year such as brackets, frames and other sheet metal parts Short lead-times Unique transportation logistic system that guarantees just-intime deliveries to all customer facilities
25 AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION AIRBUS A319-A321 AIRBUS A400M AIRBUS A350XWB Drain Mast Air Distribution Ducts Sharklet Components Drain Mast FTI Evacuation exit Insert & retainer flapsealings Ramp floor panels Load Master Workstation metal structure Air Distribution Ducts Several interior parts and assemblies
26 AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION AIRBUS A380 Anti Icing Panel, Inlet Outer Barrel Brackets, upper floor crossbeams Exhaust Duct for Flap-Track- Fairings Jettison components for FTF Jettison Pipes Crew rest compartment ladder Ventilation Scoop FTI Evacuation exit FTI Tail bumper For all Airbus Programmes: Detail parts & assemblies
27 AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION VARIOUS Bombardier CRJ lighting frames wings ARJ 21 Air grill retainer Autoflug NH 90 Metal part for seats, Eurofighter Metal parts for seats Lufthansa Technik Metal parts for engine cowlings & aircraft related components
28 AEROSPACE DIVISION / SPACE SPACE
29 AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS THE PHOENIX PROJECT Aljo delivered the test flight unit of a reusable space transport system. The complete set from component manufacturing up to the final assembly was made by aljo
30 AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS MANNED SPACE MISSIONS We delivered experimental equipment, containers and structure parts for several European Spacelabmissions, Space Shuttle flights and the International Space Station ISS
31 AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS LAUNCHERS Aljo is a main supplier of the world's most successful carrier system, -Ariane. 85 sets of complete structures of the 2nd stage and heat shield for Ariane 4 systems were supplied. We are currently involved in the Ariane 5 project with several parts and subassemblies
32 AEROSPACE DIVISION / SPACE PRODUCT SOLUTIONS GALILEO PROJECT Aljo has been involved with the manufacturing of components and structures for several satellite programs such as Meteosat, Rosat or Abrixas. Recently we finished the production of structures for the Galileo satellites
33 AEROSPACE DIVISION / AVIATION PROGRAM PARTICIPATION VARIOUS Astrium: Ariane 5: Single parts, assemblies & integration devices for ESC-A Phoenix: Fuselage and structure overall Ariane 4: Complete structure of intersection for the 2nd stage Space Shuttle: Integrated Cargo Carrier OHB: Sarlupe: Panels for satellite structures Galileo : Panels, brackets & subassemblies
34 AEROSPACE DIVISION / REFERENCES CLIENTS - SELECTION
35 AEROSPACE DIVISION / QUALITY MANAGEMENT QUALITY MANAGEMENT DESCRIPTION EN 9100 NADCAP DIN EN ISO EN ISO EN DVS /IIW 1170 DVS /EWF 3301 SCOPE AVIATION HEAT TREATING QUALITY REQUIREMENTS FOR FUSION WELDING OF METALLIC MATERIALS- PART 2: COMPREHENSIVE QUALITY REQUIREMENTS QUALIFICATION TEST OF WELDERS - FUSION WELDING - ALUMINIUM QUALIFICATION TEST OF WELDERS - FUSION WELDING - STEELS INTERNATIONAL WELDING ENGINEER EUROPEAN ADHESIVE SPECIALIST
36 ALJO PLANT DEVELOPMENT Today Tomorrow
37 THANK YOU! FOR FURTHER INFORMATION PLEASE CONTACT US! ADDRESS: ALJO ALUMINIUM-BAU JONUSCHEIT GMBH GEWERBESTRASSE BERNE GERMANY CONTACT: MR MATTHIAS SCHÜLER PHONE: +49 (0) FAX: +49 (0) matthias.schueler@aljo.de
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