Part Quality Guarantee.

Donlouco takes great care in manufacturing parts to the highest possible quality standards.

Our quality guarantee ensures that physical dimensions and tolerances are met, including surface finishes, shape and form. Materials and manufacturing processes are consistently monitored and checked including independent analysis by internationally recognised test laboratories worldwide.

 

SGS Test Results for Cylinder Trunnion.

 

Tensile Testing:

This is a critical test to determine a material's strength, yield strength, and ultimate strength. Parts can be tested in multiple directions and orientations to understand their performance characteristics, including processing, heat treatment, etc.

 

Cored Specimen Test.

Test specimens were taken in the X, Y, and Z orientations to properly evaluate the material performance of the part sample.

Each specimen was cored from the part using the wire-cut EDM (Electrical Discharge Machining) process.

 
 
 
 

Hardness Testing.

Determines the hardness level of metals and alloys, ensuring durability and wear resistance.

 
 

Impact Testing.

This is another critical test to determine a material's impact resistance or toughness. It is carried out under controlled temperatures, including -20°C, and confirms material performance against international standards.

 

Crack Detection (Non-Destructive Testing)

Uses advanced techniques to detect internal or surface flaws in the parts without causing damage. These tests include

  • Visual Inspection (VT)

  • Dye Penetrant Testing (PT)

  • Magnetic Particle Testing (MT)

  • Eddy Current Testing (ET)

  • Ultrasonic Testing (UT)

Fluorescence Magnetic Particle Inspection

Fluorescence magnetic particle inspection is a visual inspection method to detect cracks or imperfections in forged or cast parts. It can also be used to inspect other parts where these defects need to be detected. The part must be manufactured from a ferrous material for an effective inspection method.

The process consists of placing the part between magnetic induction plates and then covering the external surfaces of the part with the fluorescent liquid with magnetic particles suspended in the liquid. Because the part under inspection is magnetised the magnetic particles are retained or held in cracks and or surface defects of the part. These areas or magnetic particles can be seen or be illuminated under intense ultraviolet light exposing the defect in the part. The machine is a visual inspection aid.

Chemical Composition Testing:

Provides a detailed analysis of the material's chemical composition, ensuring the use of the correct alloys and materials.

Microstructure Analysis:

Evaluates the internal structure of metals to confirm their consistency, grain structure, and suitability for application.

 

Independent Testing.

 

Case Study: Large Cylinder Trunnion.

Project Overview:

This case study highlights the production of a large cylinder trunnion, a critical component used in heavy-duty hydraulic systems. The project involved several intricate steps, including large-scale forging, CNC machining, heat treatment, and final precision machining, with both in-house and independent testing by SGS to ensure the highest quality standards.

Key Steps in the Manufacturing Process:

1. Forging

The trunnion was initially forged from high-grade steel to create a durable base. This process was carefully monitored to ensure the material’s grain structure remained intact, providing the necessary strength and durability for the final component.

2. Rough CNC Machining

Once forged, the part underwent rough CNC machining to bring it closer to its final shape and size. This process involved removing excess material with precision to prepare the trunnion for heat treatment while maintaining tight tolerances.

3. Heat Treatment

The forged and rough-machined trunnion was then heat-treated to enhance its mechanical properties. This process improved hardness, tensile strength, and overall durability, ensuring the trunnion could withstand extreme operational stresses in its final application.

4. Final CNC Machining

After heat treatment, the trunnion underwent a final CNC machining process. This involved precision cutting to achieve the exact dimensions, tolerances, and surface finishes required by the client’s specifications. The final machining ensured a flawless fit, performance, and operational reliability in heavy hydraulic systems.

Independent Verification.

In-House + External Testing.

Reinforcing our commitment to precision, reliability and quality assurance.

Donlouco continually works with external independent inspection and verification partners for the testing of components. Hundreds of part numbers have been tested over time with highly reputable, well-known quality assurance testing companies.

Results

The large cylinder trunnion successfully passed all in-house and independent testing with no defects or deviations from the required specifications.

This project underscores Donlouco’s commitment to delivering complex parts with uncompromising quality through advanced manufacturing processes and rigorous testing. By combining our in-house expertise with external independent verification, we ensured that this particular part meets the highest standards of performance and reliability.