Jydsk Aluminium Industri

We have assisted our customers with the development of parts delivered worldwide, e.g.:

• Rear suspensions for motorbikes
• Battery cases for hybrid/electric cars
• Housing for indirect engine cooling
• Pumps for power take-off
• Housing for EGR-system (Exhaust Gas Recirculation)
• Air pipes for trucks
• Casted parts for welding on intercoolers

The parts delivered to the automobile industry are essential for the function of the customer’s end product. Accordingly, we comply with the high requirements to control/documentation of our processes to ensure correct tolerances, density, strength, purity, assembling, logistics concepts, etc.

Often the projects start with the delivery of prototypes used by the customer for different tests and for the running-in of production. Hereby the function, verification, and preparation of both the customer’s as well as JAI’s automatic production lines for seriel production are secured.

For optimal start-up and preparation of seriel production at a stable, high quality level we have, for more than 20 years, used Magmasoft casting simulation to determine flow, tension, porosities, etc.

For many years we have produced parts according to the standards of the automobile industry, and we are now in the process of being certified according to TS IATF 16949 (2018).

In order to comply with our customers’ increasing requirements to a complex design with high strength and low weight we use both tilt- and stationary casting. By both casting methods we ensure the freedom to construct parts with sand cores (coldbox). Further freedom of design is achieved by robot welding of 2 casted aluminium parts into one complex part with low weight due to the increased possibility of cavities.

To increase the strength of the part we carry out T6 or T64 heat treatment, or treatment according to customer requirements - all computer controlled in our 100% automatic heat treatment plant.

Pumps

The pump industry

For many years JAI has been System Supplier and Development Partner to the pump industry delivery gravity die cast aluminium housing. We ensure that your pump systems comply with the high requirements to density and complex canal systems. Important to the pump industry is the flexibility and the ability to adapt to the fluctuations in demand and still maintaining a high level of delivery performance.

To the pump industry we deliver small parts (3-5 kg) in high volumes casted and processed in highly automated production cells inclusing the gravity die casting proces. Competitive prices are obtained through a high level of automation and minimal internal transport. Typically, each product is produced in more machining versions, programmed specifically in the CNC cells.

JAI also produces parts up to 60 kg. to the pump industry. These parts are produced in our automated family production cells.

We offer heat treatment in our computerized and fully automated heat treatment plant ensuring high mechanical values.

Customer statement

”Parker has since 2001 used JAI as supplier and development partner of gravity die casted parts in aluminium. Our pump systems are cast at JAI in fully automatic tilt casting cells, and subsequently the different versions are finished in fully automatic CNC cells, from which they are sent direct to our assembly lines. Through all the years we have experienced a high degree of supply security, low PPM level as well as the necessary flexibility, when adjustments of the delivery plans etc. have been necessary to meet our demands.”

"Through all the years we have experienced a high degree of supply security, low PPM level as well as the necessary flexibility, when adjustments of the delivery plans etc. have been necessary to meet our demands”.

Ingemar Standoft, Sourcing and Procurement Manager, Parker Hannifin Manufacturing Sweden AB, Pump & Motor Division.

Marine industry

For many years JAI has been Development Partner within the marine industry developing and delivering parts to drives and engines as well as degas systems. A high corrosion protection is important due to the aggressive sea environment, in which the parts are used – a stable and computerized surface treatment is a must. Both functional and visual requirements are important to the end user, as some of the finished products are visible in the end product.

Typical processes are:

• Casting of up to 12 sand cores assembled into one complex sand core
• Heat treatment for optimal mechanical properties
• Leak detection with air to ensure density of the parts
• Mounting of bushings, gaskets and safety devices such as anodes, etc.
• Surface treatment with chrome 3 pre-treatment and 2-layer powder coating – for corrosion protection and visual appearance

Energy

Typical processes in connection with the manufacture of high-voltage components are the following:

• Computerized heat treatment for optimization of mechanical properties
• Robotic welding allows for more versions with less casted parts
• 100% leak detection with air and subsequently with helium up to 15 bars
• Surface treatment for high corrosion protection e.g. in maritime environments
• X-ray testing
• 3.1 certificate (traceability per part)

By means of JAI’s know-how and expertise our customers have achieved considerable savings throughout the lifetime of their products – cf. the following customer cases.

Customer Case 1: Redesign from welded steel construction into gravity die casted aluminium part

For optimization of more instrument transformers a welded steel construction was redesigned into a lighter construction of die casted aluminium parts.

In this connection we supported our customers with the following:

• Identification of possible optimization parts /projects
• Input for decision-making (business case calculations)
• Tests for mechanical properties
• Various simulations for optimal design with regard to function and mechanical properties

Our customer achieved the following advantages:

• Reduced part weight
• Less oil consumption (up to 30%) – cost-saving and eco-friendly
• Improved cooling and productivity
• Less assembly
• Improved surfaces and visual quality
• Improved corrosion protection without surface treatment

Customer Case 2: From Sand casting to gravity die casted aluminium parts

JAI has great experience in identification of customer projects suitable for gravity die casting instead of sand casting. In this way we have added value to our customers in terms of: reduced part weight, improved surface quality, improved mechanical properties, less machining, longer lifetime of the tool investment – and of course a short payback time and thereby annual savings.

Customer Case 3: Redesign of more parts into one

Due to our great experience with very complex parts and redesign of parts, we have often assisted our customers in identifying parts suitable for redesign from more parts into one product made by gravity die casting.

Thereby our customers have obtained savings due to less assembly, handling, tool investment, etc.

Robots

The robot industry is a new market for JAI strategically chosen due to the high growth rates, and matching JAI’s solutions. There are high requirements to tolerances in order to ensure the functionality of the robot.