Bringing the Automotive Industry the Right Kind of Flexible Processing Techniques...

Automotive Component Solutions

Drive Train	Brakes & Wheels	Exhaust	Fuel Systems
Steering & Suspension	Miscellaneous Components	Smaller Machines & Manufacturing Cells	Integrated Manufacturing Systems

Newcor has extensive experience with processing of just about every type of automotive component. Since 1932 we have produced over 9,000 different machines, We have one of the industry’s finest and most complete process and development laboratories with specially designed production equipment dedicated to R&D and the performance of feasibility studies. For this reason, we are among the select few suppliers that will tackle the tough jobs and produce prototypes to prove out our process, This brochure illustrates some of our proven experience and joint development programs with our customers for different processes and different materials over a variety of automotive components.

Assembly
Arc Welding
Pressing
Adhesive Application
Resistance Heating
Resistance Welding
Hot-Upsetting
Projection Welding
Testing

Arc welding of truck axle tubes and yokes.

Ten station dial projection welding machine welds electrodes into spark plug shells for 23 different plug styles at 900 per hour.

This manufacturing system assembles, epoxies, arc welds and tests ignition coil units at a 1000 per hour.

Drive Train:

Other design and build experience for drive train related parts includes:

Automotive steel rear axle tubes are resistance hot upset welded to cast differential assemblies, replacing arc puddle welds for higher quality.
Lugs are projection welded to torque converter covers at 655 per hour.
Transmission lockup rings are formed, welded, tapered, hardened and resized by an integrated production system.
Ring gear blanks in three different sizes are trimmed and resistance upset,
at 600 per hour.

Rear axle assembly and slug welding line replaces arc puddle welds with resistance slug welds.

Torque converter studs and pilots are arc welded.

Brakes and Wheels:

Other design and build experience for brake and wheel parts includes:

High-speed brake-shoe welder forms rims from flat steel and welds them to the curved web of each shoe.
Curved heavy-duty truck brake shoes use full fillet welds to assemble dual webs to shoe at 65 per hour.
Wheels are arc welded to rims of decorative truck wheels at 180 per hour.

Automotive brake-shoes are produced by welding flat steel rims to curved webs, at 1200 per hour. Automotive brake-shoes are produced by welding flat steel rims to curved webs, at 1200 per hour.

Brake backing plates are projection welded, hot upset and machined at 500 per hour. Brake backing plates are projection welded, hot upset and machined at 500 per hour.

Exhaust:

Other design and build experience for exhaust related parts includes:

Twin-pipes are simultaneously MIG welded to mufflers.
Flat 8-sided catalytic converter bodies are assembled and spot welded at 600 per hour.

Twin robots, MIG Weld inlet pipe-to-muffler applying 190 degrees of weld attaching pipes to muffler.

Newcor standard tube mill welders can continuously weld differing grades of steel tail pipes in excess of 300 fpm.

Stainless steel outlet flanges and ball-tube extensions are shrunk, pressed, tacked and arc welded.

Fuel Systems:

Other design and build experience for fuel system related parts includes:

Six-sided terne coated steel fuel tanks are properly oriented, tack welded and seam welded at 300 per hour.

Pre-coated halves of automotive fuel tanks are seam welded together.

Light gauge coated steel fuel sender tube support brackets and flanges are successfully HY-PAK® welded without damage to protective coatings.

Oxygen Sensor components are automatically assembled and tested on a Newcor palatalized assembly system.

Steering and Suspension:

Other design and build experience for suspension related parts includes:

Production vacuum testing for oil leaks of tubular base units of strut assemblies.
Steering knuckle and spindle are assembled by induction heating and pressing operation.
Steering jacket assemblies for 38 different vehicle models have ignition wiring connecting nuts and ignition clips welded in position.
Spring seats and lower control arms are arc welded to trailing axles.

Torsion bars are welded to trailing axles with unique rotating flux-cored wire welding torch at 128 per hour.

Bearings are pressed and staked into powder metal heads of shock absorber strut assemblies.

Miscellaneous Components:

Other design and build experience for miscellaneous parts includes:

Friction welding bimetallic valves for gasoline and diesel engines.
Welding and riveting are combined to assemble dip stick and oil drain components to predrawn steel oil pans.
Power-actuated auto window regulators are tested for proper assembly and operation.
Plastic fluid flow ball checks are assembled in automatic transmission valve bodies.

Automotive bumper shock mounting plates and isolator tubes are resistance hot upset.

Robotic seat frame fabrication system handles a wide variety of seat models with minimum changeover.

Smaller Machines and Manufacturing Cells:

These three stand alone machines are part of a low volume batch run manufacturing cell for piston and rod assemblies for struts. The dial machine at the top left, is a manual assembly machine for valve components. The center machine resistance spot welds the rebound stop bushing. The top right machine projection welds the piston and rod.

Completely Integrated Manufacturing Systems

NEWCOR transmission oil cooler manufacturing system fabricates and assembles two styles of coolers that differ in types of fittings and shipping plugs. Operations include tube debundling and cut off, piercing, forming, hydroforming, washing, brazing, assembly, machining, sizing, TIG welding and mass spectrometer leak testing.