process

Production

Production Process

All raw materials like metal sheets, fluxes, welding wires, paint and semi finished products like valve guards, foot rings valves are accepted to the production area after quality checks which are realized according to the quality control plan. AEAL arranges its facilities to reject any raw materials or semi finished products that do not meet the required quality specifications.

The cylinders are manufactured from two or three pieces. During production of two piece cylinders two halves are produced by a deep drawings process by the hydraulic presses.
After which, the cylinder halves are cut, trimmed and joggled. The halves together with the ready formed valve guards and foot rings are passed through the degreasing unit where they are washed to remove the oil in readiness for welding.

After the cleaning; the valves boss, valve guards and foot rings are welded onto the top and bottom halves of the cylinders. The welding process is fully automated gas shielded submerged arc welding. The fitted drawn halves are then welded by a single pass circumferential welding lap in the automatic welding machines to obtain a sound weld with the deep penetration. All welding operations are performed according to welding procedures by certified welders. Additionally, all welding parameters are simultaneously followed by engineers and monitored and recorded into computers.

High capacity cylinders are fabricated from three pieces. Such a cylinder consists of cylindrical shell rolled and butt welded in automatic submerged metal arc welding process longitudinally and two deep drawn ends which are cut, trimmed and joggle joint formed.
These are connected to the shell circumferentially by automatic submerged arc welding process.

In the Middle

After the welding operations, the cylinders are normalized to enable the material to regain its original properties. Cylinders are uniformly heated by passing through a high temperature furnace. The moving speed of the cylinders through the furnace as well as the heating and cooling cycle periods and temperatures can be adjusted to restore the material into the original mechanical conditions.

After the normalization process, all the cylinders are hydro-statically tested. In order to achieve good bonding of the anti-rust paint, each cylinder surface is externally blasted with steel shots until clean while metal surface is obtained.

The cylinders then pass through a fully automated paint coating line where the surface is first cleaned with compressed air. The powder paint is then sprayed onto the cylinder. The paint is then cured at a temperature of 200 degrees C and then cooled.

At the End

Following the painting process, the threads are cleaned to remove possible grit, zinc, paint and other foreign material. The cylinders are then fitted with the valves and then submitted to a leakage test. The cylinders are then consecutively weighed and the tare weight is
marked. Serigraphy is then applied onto the cylinders according to the customers demand. All cylinders are covered with plastic nets to ensure secure delivery without damage.