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Comprehensive welding expertise that meets your requirements

When it comes to aluminium profiles, a key aspect for the future purpose of the profile is further processing based on customer requirements. Here we draw on many years of comprehensive expertise in all types of welding. This enables us to respond very quickly to customers’ specific needs and deliver the results they want.

STEP-G customers appreciate the high quality of our automatic and manual processing of their custom aluminium profiles and assemblies. Our welding specialists mostly use the MIG method. 

Large-profile welding machine

We process large components and ready-to-install assemblies such as side walls, roofs and floor panels for rail vehicles on our large-profile welding machine. A significant advantage of STEP-G’s longitudinal seam welding machine is its welding fixtures, which are capable of clamping and processing components measuring up to 4.000 x 25.000 millimetres. The machine features two MIG torches with a laser seam guide system that guarantees high process stability and precision. This achieves faster cycle times than a single torch. Using our large-profile welding machine, we can optimally weld any seam shapes exactly to customer specifications. 

We benefit from our flexible clamping system when welding large profiles. The clamping technology holds the individual assemblies upright on the base support and turns them into the right position for each welding process. When the assembly is in place, the machine precision-welds it automatically. The large-profile welding machine comes into its own especially for welding within narrow tolerances. It produces high-quality weld seams positioned with pinpoint accuracy. 

Robotic welding system

Text: Today we need to achieve ever-higher efficiency in manufacturing for industries as varied as general and rail vehicle construction and machine and plant engineering. That’s why we increasingly use robotic welding systems. Robotic welding systems are also essential in the construction industry to guarantee high tolerances and precision. Our robotic welding system features an integrated rotary table and flexible clamping technology. This gives us great flexibility in the design of the welding process. It also enables rapid adjustment to customer requirements for new contours. The machine can weld dimensions of up to 2,500 x 22,000 millimetres with high reproduction accuracy. The welding torch is equipped with a laser-controlled seam guide system to ensure optimum tracking. This system uses the CMT welding method with low heat input to ensure extremely low distortion. 

Universal welding system

Our universal welding system is a versatile machine with a pivoting boom that makes it possible to weld dimensions of up to 3,000 x 12,000 millimetres. The installation of the universal welding system provides the option of welding transverse and longitudinal seams in a single clamping position. We use it especially for complex assemblies such as cross beams, stems and side walls for rail vehicle construction as well as aluminium components for the automotive industry.

Assembly production with MIG and TIG welding

MIG welding is the most commonly used type of welding. In this process, all the required individual parts and subassemblies for large assemblies are precisely positioned and welded together. MIG (metal inert gas) welding is suitable for a broad range of applications. 

TIG (tungsten inert gas) welding above all produces high-strength weld seams and is an important method for welding thin-walled aluminium profiles. STEP-G is ideally equipped for manual welding, with sufficient MIG and TIG welding power sources as well as turning units that rotate and lift for optimal workpiece positioning. Since the 1970s, STEP-G has drawn on comprehensive expertise in applying this welding technology. That makes us an expert partner for further processing aluminium profiles by welding.

Component inspection and testing for quality assurance

At STEP-G, we not only meet, but also guarantee our customers’ quality requirements. To do this, we can apply all common inspection and test methods for the evaluation of welded assemblies and large components. These consist of visual inspection, dye penetrant testing and ultrasound and x-ray scanning.

We use laser trackers and laser scanners as well as coordinate measuring machines to check the dimensional accuracy of our products. In our in-house test lab, we perform and document the results of all common material tests (bending, tensile and hardness tests, notch impact tests, micro and macro analyses and material analyses). This ensures that not only STEP-G, but also our customers can rely on top safety and quality standards.

Regular staff qualification

The skills of all STEP-G welders and welding machine operators are regularly verified by qualification testing in compliance with EN ISO 9606-2. We also test their qualification with additional, project-specific work samples. Yearly training, instruction and further training courses guarantee the consistent high-quality welding skills of our employees. We train future new staff in our own in-house apprenticeship workshop. This is how we pass on our welding knowledge and enthusiasm to youngsters early on in their careers and support young talents. Our apprenticeships aim to supply us with tomorrow’s qualified staff who can then grow in our company.

Welding certification in compliance with EN 15085-2

Our STEP-G location in Bonn Bonn is an approved and certified welding company for rail vehicles and parts in compliance with EN 15085-2, certification level C1.