The evolution of welding is accelerating with the incorporation of smart technologies, automation and high-precision laser solutions. The industry is taking firm steps towards more efficient, connected and faster production, with concepts such as Industry 4.0, robotics and simplicity of use redefining the standards of quality and competitiveness in the metalworking sector. We talk about it all with leading voices in the industry below.

What are the benefits of new advanced welding techniques in production processes?

The rotary friction stir welding techniques that we implement in Berkoa offer key advantages in terms of reliability, efficiency and quality. This welding technology fuses two parts of the same or different materials with highly resistant results. Some examples are the joints between forging and steel for the automotive sector, F114 and HSS in tools, or even aluminium and copper in applications such as power lines.one of the most representative examples to understand the strength and reliability of these joints is in the manufacture of tools, such as drills. In this case, a joint between high-speed steel and F-114 is achieved that fully maintains the characteristics of the tool, as if it were made entirely of this material, but with additional advantages in terms of cost.from the production point of view, this technology allows the process to be repeated with precision, generating very little waste and maintaining a constant quality in the joints, which contributes to reducing both manufacturing times and costs.

What are the main challenges you have faced when implementing this type of solution?

One of Berkoa’s major technological milestones has been the development of SoldAvanza, our advanced welding machine, which is currently operational in our facilities for subcontracting services: prototype manufacturing, trials and tests. The biggest challenge has been the implementation of the BLSC 4.0 registered controller, co-designed together with the Lortek technology centre. This system makes it possible to accurately manage all process parameters, facilitating real-time control, optimising adjustments and improving traceability. Its ability to be integrated into automated environments makes it a key pillar for the industry that is looking to move towards more digitalised environments.at Berkoa, we are the only national manufacturer of rotary friction welding machines and we have manufactured several units of this type of machinery that have the controller integrated. Among the most outstanding are the automatic cell with robots for loading and unloading, designed to optimise welding processes in industrial environments. n addition, we manufactured a machine model BFW40/2000, with integrated turning for the elimination of burrs, which was delivered to Izar Cutting Tools, a company specialising in cutting tools. This machine enables the joining of the aforementioned materials, such as high-speed steel and F-114, contributing to the optimisation of the production of high-precision tools such as drills and other cutting components.

Which technologies do you think will have the greatest impact in the coming years?

At Berkoa, we believe that technologies that provide real value in terms of efficiency, sustainability and cost reduction will be the most relevant in the coming years. These include smart process control, cloud connectivity, real-time data analysis, advanced traceability systems, as well as support tools such as digital twins and augmented reality, which not only optimise manufacturing processes, but also have a direct impact on the circular economy. At Berkoa, we understand the circular economy through the retrofitting of machinery, which makes it possible to extend the useful life of equipment and reduce production costs without the need to invest in new equipment. Similarly, the BLSC 4.0 controller, developed internally at Berkoa in collaboration with Lortek, optimises process control and improves efficiency, which also contributes to cost reduction and improves the sustainability of production processes.

What solutions does your company offer in this field?

At Berkoa, we specialise in the design and manufacture of customised machine tools, adapted to the specific needs of each customer. Our motto, ‘You name it, we make it!’, perfectly reflects our values. In addition to offering new machinery, we provide retrofitting solutions that optimise the service life and performance of existing equipment. In the field of advanced welding, we not only manufacture rotary friction welding machines, but we also retrofit this type of machinery. We have, on the one hand, the registered BLSC 4.0 controller, as mentioned above, but we are also currently involved in a new project together with Lortek and VORS Control, in which we have developed a digital twin of the forging actuator and the welding process. This advance guarantees optimum behaviour of the system, allowing us to optimise parameters such as pressure, torque, speed and position in order to be able to control the machine with the quality specifications required by the sector.

Interview with Andoni Garcia-Abad, Managing Director of Berkoa.
Source: Metales&Máquinas