Ground tapping method
Highly productive melting and casting process for complex components made of highly heat-resistant materials. Large quantities can also be produced in a short period of time with a very high level of reproducibility.

• From individual parts to large series
• High degree of purity
• Possibility of targeted grain refinement on the castings
• High degree of automation

Tilting crucible method
Melting and casting process for the production of complex components made of high-temperature resistant materials with a high purity and very good reproducibility.

• From individual parts to large series
• Very high degree of purity
• High degree of automation in production, autonomous casting by casting cell (pre-heating to cooling)

Conventional method

The conventional open investment casting - is a lost wax process that is characterised by an almost unlimited selection of alloys.

• Component weight up to 100 kg
• Manual pouring off of the casting cluster in an oxygenated environment
• The mould is filled manually via a ladle and is controlled by the casting speed
• Maximum installation space 600 x 600 x 550 mm

Roll-over technology

A very high material quality is achieved with roll-over technology. After melting the alloy, the furnace rotates 180 degrees in a few seconds. The mould shell that is flanged directly to the furnace is filled precisely and with low turbulence in the process, also while using inert gas.

• The influence of oxygen is eliminated by using an inert gas bell.
• The maximum installation space is 580 x 400 mm diameter
• Maximum casting weight of 100 kg

The sand casting process offers a high degree of freedom and the economic production of complex components with undercuts and cavities

• For individual parts and small series
• Production according to the permanent model, lost model or based on printed/milled moulded parts
• Part weights: Copper alloys up to 8,000 kg, steel alloys up to 2,500 kg
• Production using a lost mould

Complex components with cavities and a high surface quality can be economically produced with Croning casting or shell casting.

• Surface quality Ra 6.3 µm
• Large series
• Metallic models
• Weight range up to about 20 kg
• Part dimensions up to about 400 x 250 x 200 mm
• Production using a lost mould

Ceramic casting is particularly well-suited for thin-walled components and high degrees of purity when casting special materials

• Non-reactive moulding material
• suitable for cores and moulds
• Part dimensions 1400 x 1400 x 600 mm
• Production using a lost mould

Round solid material is economically produced from copper alloys in the continuous casting process

• Diameter 120 to 620 mm
• Length up to 2,400 mm
• Production using a permanent mould

The centrifugal casting process is particularly well-suited for the economic production of rotationally-symmetrical bushings

• Diameter up to 640 mm
• Length up to 800 mm
• Weight: max. 400 kg
• Production using a permanent mould

ZOLLERN produces round and square workpieces, from shafts to flat bars, with several pneumatic hammers and a 1,600 tonne hydraulic forging press.

Dimensions of the workpieces
Diameter: 40 - 500 mm
Lengths: 1 - 10 m

In ring rolling, an ingot blank is placed on the forging press and rolled onto the ring rolling mill.

Dimensions and weight of the seamlessly rolled rings
Diameter: up to 2,500 mm
Unit weight: up to 250 kg

Drop forging or stamping are particularly well-suited for the production of larger quantities.

Weight of the forged parts
Unit weights: up to 15 kg

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences

With hot rolling, the raw material is inductively heated and rolled into a raw profile in several automated pass sequences.

With cold drawing, the pre-formed hot rolled profile is drawn one or multiple times by a carbide die and brought into the desired shape. Stress introduced is neutralised between the forming steps via heat treatment.

With cold rolling, a wire rod is brought into the specified final contour at room temperature by rolling. Several rolling units in a production line automatically perform this process and give the profiles a high surface quality. The process is particularly well-suited for manufacturing small profile geometries, which are needed in larger quantities.

ZOLLERN uses inductive hardening to increase the wear resistance of the profile surfaces. Hardening depths of 0.5 to 5 millimetres and hardness values of up to 64 HRC are achieved.